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DOE OSTI2018

Influence of High Pulsed Magnetic Field on the Dislocations and Mechanical Properties of Al{sub 2}O{sub 3}/Al Composites

At T6 state, Al–Zn–Mg–Cu aluminum matrix composites reinforced with Al{sub 2}O{sub 3} particles generated in situ were subjected to high pulsed magnetic fields at different magnetic induction intensities (B = 2, 3 and 4 T). The results show that the dislocation densities in the treated samples increased with increasing B, and the magnetoplastic effect was determined to be the primary cause. The effect of the magnetic field is believed to alter the spin state of free electrons between dislocations and obstacles from the singlet state (associated with high bonding energy) to the triplet state (low bonding energy). The maximum ultimate tensile strength of 532 MPa was obtained at B = 4 T with 30 pulses, which was 20.7% higher than that of the initial sample, primarily because of dislocation strengthening. At B = 2 T, the elongation was at its maximum of 9.3%, representing an increase of 12% compared with the initial sample, while the associated ultimate tensile strength (447 MPa) was still higher than that of the untreated sample (440 MPa). The relationship between mechanical properties and microstructure was analyzed, and the improved properties observed in this work are explained by the transition of the electron spin state and the piling up of dislocations.

36 MATERIALS SCIENCE↗

NASA NTRS2003

Versatile Turbine Disk Alloy Designed and Processed for Higher Temperature Applications

Advanced turbine engine configurations using higher temperature combustor and airfoil concepts require compressor and turbine disks that can withstand temperatures higher than the 650 C typical of current engines. This requires disk alloy and processing improvements. A versatile disk alloy was needed that could be given either fine grain heat treatments for high strength and fatigue and creep resistance up to 704 C or given coarse grain heat treatments for high strength and creep and dwell crack-growth resistance at higher temperatures. This alloy could produce disks with uniform microstructures and properties, as well as with varied, optimized microstructures at disk bore and rim sections. A series of experimental disk alloys were designed and processed to give subscale disks about 13 cm in diameter and 4 cm thick. These alloys had varying levels of key elements to affect mechanical properties and change the "solvus" solution heat-treatment temperature necessary to produce coarse grain microstructures. Disks were given coarse grain heat treatments followed by rapid oil quenching and slower fan air quenching. These heat treatments were intended to simulate the cooling paths of rapidly cooled full-scale disks at the outermost rim and interior bore locations, respectively. Preliminary quench tests of tensile specimens and coin-size minidisks had indicated that alloys having high solvus temperatures were more prone to cracking during rapid quenching from coarse grain heat treatments. These findings were confirmed in the subscale disks, where such alloys did form undesirable quench cracks. Mechanical tests were performed on specimens from subscale disks given these coarse grain heat treatments, as well as on specimens given a fine grain heat treatment. Tensile, creep, and crack growth tests were performed at 704 C and higher temperatures. A versatile alloy was identified that had a low solvus temperature for resistance to quench cracking as well as an optimal combination of high levels of strengthening refractory elements that produced balanced high mechanical properties for both fine grain and coarse grain microstructures. This low-solvus, high-refractory (LSHR) alloy has been scaled-up to produce prototype full-scale turbine disks typical of regional jet turbofan engines. Disks were successfully heat treated to give uniform coarse grain and uniform fine grain microstructures. Additional disks were given a NASA dual microstructure heat treatment (DMHT) that intentionally varied the solution heat-treatment temperatures between the disk rim and bore (re f. 1). The disk rim was heated to a high enough temperature to produce a coarse grain microstructure, while the bore was maintained at a lower temperature to produce a fine grain microstructure (see the figure). This DMHT can produce optimal high strength, fatigue, and creep resistance up to 704 C in the cooler running disk bore, and high strength, creep resistance, and dwell crack growth resistance at higher temperatures for the hotter disk rim. Extensive mechanical testing is being initiated to compare the mechanical properties of the uniform and DMHT disks.

Gabb, TImothy P.↗

DOE OSTI2021

A microstructure-based modeling approach to predict the mechanical properties of Zr alloy with hydride precipitates

In nuclear reactors, hydrides can form in fuel cladding due to hydrogen absorption in ZIrcaloy and cause embrittlement. This work presents a microstructure-based finite element model to predict the stress-strain response of Zircaloy containing hydrides. Quantitative microstructural details extracted from scanning electron microscopy (SEM) images were used to generate heterogeneous microstructures including the morphology and spatial distribution of hydrides. The constitutive material model for zircaloy in this study is based on crystal plasticity theory which considers the hexagonal close-packed (HCP) atomic structure of Zircaloy material. The hydrides were modeled as brittle material along with a damage model. Hydride formation inside the zircoloy matrix results in residual stress. This phenomenon is also captured in this model. A parametric study has been conducted to understand the effect of volume fraction, orientation, and lamellae thickness of the hydride phase on the mechanical properties of the overall material.

Kulkarni, Shank S.↗

DOE OSTI2023

Assessment of Process Modeling Tools for Determining Variability in Additively Manufactured Parts

The Advanced Materials and Manufacturing Technologies (AMMT) program aims to accelerate the development, qualification, demonstration, and deployment of advanced materials and manufacturing technologies to enable reliable and economical nuclear energy However, the unique aspects of additive manufacturing (AM) materials in terms of their processing history, microstructure, and properties, are a major barrier for qualification and certification of nuclear components. Much of this challenge may be attributed to component scale variations in microstructure and properties that are driven by local influences of process conditions and geometry on thermal history, melt pool dynamics, and corresponding microstructure evolution. Computational modeling tools may be helpful in this regard to aid in predicting and controlling this level of variability. The purpose of this report is to review the current state-of-the-art for process modeling with regards to metal AM. For this purpose, we consider specifically the case study of laser powder bed fusion (LPBF) processing of SS316, a family of alloys that are both commonly used in nuclear energy applications and suitable for AM processing. The report first introduces the necessary components of a process modeling workflow, followed by a review of the current status of each. At the end, application of these modeling tools to understanding variability in AM process given their current state are considered, and recommendations for future development are proposed

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 OSTI2018

Explicit Backscattering Coefficient for Ultrasonic Wave Propagating in Hexagonal Polycrystals with Fiber Texture

Hexagonal polycrystalline materials such as titanium, zirconium and magnesium are common in engineering structures like car bodies and airplane engines. These components are usually specially designed in microstructure level to guarantee desired mechanical properties, so microstructure characterization is of great importance to the optimization of manufacturing processes. Compared with traditional destructive characterization methods like scanning electron microscopy (SEM), the ultrasonic approach is nondestructive and cost-effective. Although some progress has been made in ultrasonic microstructure characterization of polycrystal aggregates of hexagonal grains, some factors like macro texture and grain size distribution associated with realistic microstructures were not accounted for yet. Targeting one common texture component for hexagonal polycrystalline materials, {0001} basal fiber texture, this paper derived the explicit backscattering coefficient for aggregates of ellipsoidal grains through one texture parameter and obtained an analytical backscattering coefficient for microstructures with various grain size distributions. In this study, the basal fiber texture was quantified by the 1D Gaussian orientation distribution function (ODF), which merely includes one texture parameter, and its relationship with generalized spherical harmonics ODF was also addressed. Moreover, explicit expressions for effective elastic moduli and elastic constant covariances were derived. Furthermore, some computational examples were given to demonstrate the impacts of texture, frequency, grain geometry and grain size distribution on backscattering behavior. The theoretical results in this study will greatly benefit the later ultrasonic microstructure characterization of hexagonal polycrystalline materials.

42 ENGINEERING↗

DOE OSTI2018

Microstructure Evolution and Mechanical Properties of Keyhole Repair Welds in AA 2219-T851 Using Refill Friction Stir Spot Welding

The search for a suitable friction-based keyhole repair technique that fulfills the requirements for high-quality repair welds has become an important research topic, especially for aerospace applications. In order to provide and analyze an universal keyhole repair method for lightweight metals, refill friction stir spot welding is applied to through-hole repairs in 3- and 6-mm-thick sheets of precipitate hardening AA 2219-T851. Keyholes with a diameter of 7.5 mm were repair welded achieving a defect-free microstructure. The correlation between the microstructural evolution imposed by the repair process and the resulting mechanical properties is shown. A comprehensive analysis of the precipitate evolution in peak-aged AA 2219 during RFSSW is presented. Thermal cycle measurements revealed high heating rates and peak temperatures of up to 520 °C in the weld center. The thermal cycle caused mainly dissolution and minor equilibrium phase formation in the stirred zone. In the HAZ, overaging of the strengthening precipitates dominates with minor dissolution and equilibrium phase formation only in the direct proximity of the SZ. Microstructural analysis revealed typical weld zone formation with inhomogeneous grain size distribution in the SZ. The resulting mechanical properties are dominated by an inhomogeneous hardness distribution with lowest hardness in the TMAZ at 5 mm from the center of the weld. During tensile loading main yielding and the final fracture occur in the area of lowest strength. Tensile testing showed yield strength of 40 to 46% and UTS of 28 to 25% below BM values in 3- and 6-mm-thick sheets, respectively. The sheet thickness and post-weld natural aging were found to influence the mechanical properties of the weld significantly.

36 MATERIALS SCIENCE↗

DOE OSTI2026

TEM Approaches for Microstructure-Informed Prediction of Mechanical Properties in Structural Alloys

Predicting the mechanical performance of structural alloys from their evolving microstructure remains a major challenge in materials science, particularly for nuclear structural materials, where irradiation-induced defects span multiple types and length scales and interact through complex mechanisms. The dispersed barrier hardening (DBH) [1] and Friedel–Kroupa–Hirsch (FKH) [2,3] models have been widely used to evaluate the hardening contributions of individual obstacles and to estimate tensile strength from quantified microstructures; however, when multiple size-dependent obstacles coexist and evolve, predicting temperature-dependent tensile strength becomes significantly more complex, and a fully consistent hardening model is still lacking. Transmission electron microscopy (TEM) plays a central role in refining hardening models and enabling predictive assessments of tensile strength evolution by providing quantitative characterization of dislocations, irradiation-induced defects (e.g., dislocation loops and cavities), precipitates, and grain structure (Fig. 1.). These experimentally measured defect densities are incorporated into physically based hardening models with size- and shape- dependent obstacle strengths [4], using root-sum-square superposition for obstacles of comparable strength and linear superposition for dissimilar ones [5]. In addition, recent advances in TEM [6-8], including high-resolution imaging, 4D-STEM strain mapping, EDS/EELS elemental analysis, and flash-polishing-based TEM specimen preparation and extraction-replica methods (Fig. 2), further improve the accuracy of microstructural quantification. By comparison with prior studies as well as our own results, we show that when TEM-derived microstructural information is carefully integrated with physically grounded hardening models, yield strength (or irradiation-induced hardening) measured at room temperature can be predicted with good quantitative agreement across multiple alloy classes. In-situ TEM combined with high-temperature mechanical testing represents an important next step for refining hardening models by directly probing dislocation–obstacle interactions across varying irradiation doses and temperatures [9]. Because the barrier strength factor (α) depends on both temperature and obstacle size, it should not be treated as a constant fitting parameter; rather, it must be explicitly evaluated to achieve physically meaningful predictions of mechanical behaviour at operating temperatures. This presentation therefore discusses why all strengthening contributions (e.g., Peierls stress, solid-solution strengthening, voids, bubbles, dislocation loops, dislocation lines, and grain boundaries) must be considered collectively, why appropriate superposition methods are essential when obstacles possess different barrier strength factors, how hardness measurements can be meaningfully related to tensile properties, and how TEM-derived microstructural information can be systematically incorporated into hardening models. More broadly, it outlines a pathway toward microstructure-informed prediction of mechanical properties and supports the goal of establishing science-based tools for evaluating structural materials in extreme environments [10].

Lin, Yan-Ru [ORNL] (ORCID:0000000339991473)↗

DOE OSTI2024

Creep Resistant Martensitic Steels for Operation at High-Temperatures in Power Generation Applications

Increasing the temperature capabilities of ferritic/martensitic 9-12% Cr steels can help in increasing the operating temperature of land-based turbines and minimize the use of expensive high-temperature alloys in the hot section. A creep resistant martensitic steel, JMP, was developed with the potential to operate at or above 650°C. The design of the alloys originated from computational modeling for phase stability and precipitate strengthening using fifteen constituent elements. Cobalt was used for increased solid solution strengthening, Si for oxidation resistance and different W and Mo concentrations for matrix strength and stability. The JMP steels showed increases in creep life compared to MARBN/SAVE12AD at 650°C for testing at various stresses between 138 MPa and 207 MPa. On a Larson-Miller plot, the performance of the JMP steels surpasses that of state-of-the-art MARBN steel. Approximately 21 years of cumulative creep data are reported for the JMP steels which encompasses various compositions. The relationships between composition-microstructure-creep properties are discussed including characterization of microstructures after >20,000 hours in creep.

Detrois, Martin↗

DOE OSTI2019

Spark Plasma Extrusion and the Thermal Barrier Concept

Spark plasma sintering (SPS) is currently a major powder consolidation process with many advantages; however, it is still largely limited to the processing of simple shapes such as discs due to its geometric restrictions. Alternatively, spark plasma extrusion (SPE) is a recently developed process that has superiority over SPS in terms of faster consolidation, generating products of extended geometries and potential grain refinement capabilities under applied current. So far, work on SPE has resulted in large temperature gradients within the extruding material with microstructural and properties in-homogeneities. The present paper reports on a novel approach (thermal barrier concept) that allows the SPE of materials with enhanced uniformity in terms of microstructures and properties. Both aluminum and aluminum-carbon nanotube composites have been successfully processed using this new approach.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2018

Formation and Properties of Locally Tensile Strained Ge Microstructures for Silicon Photonics

The formation and properties of locally tensile strained Ge microstructures (“microbridges”) based on Ge layers grown on silicon substrates are investigated. The elastic-strain distribution in suspended Ge microbridges is analyzed theoretically. This analysis indicates that, in order to attain the maximum tensile strain within a microbridge, the accumulation of strain in all corners of the fabricated microstructure has to be minimized. Measurements of the local strain using Raman scattering show significant enhancement of the tensile strain from 0.2–0.25% in the initial Ge film to ~2.4% in the Ge microbridges. A considerable increase in the luminescence intensity and significant modification of its spectrum in the regions of maximum tensile strain in Ge microbridges and in their vicinity as compared to weakly strained regions of the initial Ge film is demonstrated by microphotoluminescence spectroscopy.

36 MATERIALS SCIENCE↗

NASA NTRS1987

Effect of the microstructure on the thermoelectric properties of polycrystalline lanthanum chalcogenides

Small amounts of second phase materials can have important effects on the thermoelectric properties of polycrystalline gamma-La(3-x)X4 (X-S, Te; X in the range of 0 to 1/3). Microscopic examination by SEM of hot pressed La(3-x)Te4 samples has revealed from 1-5 vol. pct of La2O2Te, an amount which is not detected by X-ray powder diffraction measurements. This amount of La2O2Te resulting from oxygen contamination can reduce the concentration of electrons by as much as 10 to 75 percent below the electron concentration calculated for single phase La(3-x)Te4 in the composition range of greatest interest. Small amounts of second phase materials can also lower the lattice thermal conductivity by scattering low frequency phonons. These results indicate that microstructural effects should be considered when electrical and thermal properties of polycrystalline materials are analyzed.

Lockwood, A.↗

DOE OSTI2025

Microstructure, mechanical, and thermal properties of compositionally complex (Hf,Zr,Nb,Ti)B 2 ‒LaB 6 ceramics

Novel compositionally complex borides, (Hf,Zr,Nb,Ti)B 2 and (Hf,Zr,Nb,Ti)B 2 ‒LaB 6 , were fabricated using spark plasma sintering process. (Hf,Zr,Nb,Ti)B 2 ‒LaB 6 exhibits a dual-phase microstructure, in which (Hf,Zr,Nb,Ti)B 2 is a primary phase with the hexagonal structure and LaB 6 is a secondary phase with a cubic structure. The mechanical properties of both (Hf,Zr,Nb,Ti)B 2 and (Hf,Zr,Nb,Ti)B 2 ‒LaB 6 are comparable, with a combination of high hardness and moderate fracture toughness. Thermal diffusivity and conductivity of (Hf,Zr,Nb,Ti)B 2 are much lower than the individual transition metal borides but are significantly increased by the addition of LaB 6 . Herein, it is implied that the thermal properties of boride ceramics can be controlled through the appropriate design of principal metal element compositions.

borides↗

DOE OSTI2021

Effect of hatch spacing and laser power on microstructure, texture, and thermomechanical properties of laser powder bed fusion (L-PBF) additively manufactured NiTi

This study systematically evaluates the effects of laser powder bed fusion additive manufacturing (L-PBF-AM) parameters (hatch spacing and laser power) on the thermomechanical behavior and microstructure of Ni 50.8 Ti 49.2 shape memory alloy. The samples were fabricated with hatch spacings from 40 to 240 µm and laser powers of 50 and 100 W at a constant scanning speed of 125 mm/s, resulting in parts with volumetric energy density levels from 55 to 666 J/mm 3 and two sets of linear energy densities of 0.4 and 0.8 J/mm. The results showed a reduced melt pool size and discontinuity of scan tracks with decreased laser power. Additionally, the porosity level was increased with larger hatch spacing and lower laser power. More notably, the transformation temperatures increased, and the critical stress, recoverable strain, and functional stability of samples improved with lower hatch spacing, where the recovery ratio of up to 90% was observed, regardless of the employed laser power. This study also discussed the relationship between the fabrication process and texture formation in the L-PBF-AM process. In conclusion, the advantage of L-PBF-AM was revealed in tailoring the microstructure from highly textured samples in [1 1 1] or [0 0 1] direction when hatch spacing lower than laser beam focused was employed, to the appearance of equiaxed solidification front with island grains and random orientations.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Pre-Irradiation Comparison of W-Based Alloys for the PHENIX Campaign: Microstructure, Composition, and Mechanical Properties

Tungsten is the material of choice as the plasma-facing material in future plasma-burning fusion reactors. During operation, plasma-facing materials will be simultaneously exposed to 14-MeV neutrons, low-energy D/He particles, and high heat loads. Neutron irradiation of tungsten results in bulk material damage, including knock-on damage causing loops and voids, and transmutation reactions leading to the transmutation of tungsten to rhenium and osmium. Under irradiation to high dose, Re and Os atoms can amalgamate into precipitates that drastically alter the material properties, noticeably increasing the hardness. However, the early-stage development of Re and Os precipitates under a fast neutron spectrum has not been investigated.In this work, the microstructure and hardening behavior of W-Re alloys containing 0 to 2.2 wt% Re, TiC-doped W, and powder-injection-molded W are investigated prior to neutron irradiation at 500ºC and 800ºC to ~0.1 displacement per atom in the High Flux Isotope Reactor (HFIR) to establish a baseline understanding of the starting microstructures.Transmission electron microscopy analysis indicates a dislocation-heavy microstructure, and scanning transmission electron microscopy–energy dispersive spectroscopy shows no spatial segregation of Re and W. Similarly, surface compositional studies performed with electron backscatter diffraction and X-ray photoelectron spectroscopy showed no presence of Re, indicating the Re did not segregate or form new phases during fabrication. Here, the alloys in their as-fabricated state showed no Re segregation or second-phase development, with no significant differences between their microstructures and Vickers hardness values.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Influence of Bi addition on the property of Ag-Bi nano-composite coatings

Silver (Ag) coatings have been widely used in many industry areas due to their excellent conductivity. However, wider applications of Ag coatings have been hindered by their poor mechanical properties. In this research, to improve the mechanical performance, Ag-Bi nano-composite coatings were prepared by a novel ionic co-discharge method. A systematic study of the microstructure, mechanical properties, electrical conductivity and antibacterial behavior of the resulting coating was performed. The results indicated that after adding an appropriate amount of Bi containing solution into the Ag plating solution, Ag-Bi nanoparticles were in-situ formed and distributed uniformly throughout the coating matrix, resulting in a significant improvement in the mechanical properties. The hardness of Ag-Bi coating was increased by 60% compared to that of the pure Ag coating. The corrosion resistance of Ag-Bi coatings was also enhanced. The Ag-Bi coatings prepared in the current study will find a broader application in electronics, jewelry, aerospace and other industries.

36 MATERIALS SCIENCE↗

NASA NTRS2000

Gravitational Effects on Combustion Synthesis of Advanced Porous Materials

Combustion Synthesis (self-Propagating high-temperature synthesis-(SHS)) of porous Ti-TiB(x), composite materials has been studied with respect to the sensitivity to the SHS reaction parameters of stoichiometry, green density, gasifying agents, ambient pressure, diluents and gravity. The main objective of this research program is to engineer the required porosity and mechanical properties into the composite materials to meet the requirements of a consumer, such as for the application of bone replacement materials. Gravity serves to restrict the gas expansion and the liquid movement during SHS reaction. As a result, gravitational forces affect the microstructure and properties of the SHS products. Reacting these SHS systems in low gravity in the KC-135 aircraft has extended the ability to form porous products. This paper will emphasize the effects of gravity (low g, 1g and 2g) on the SHS reaction process, and the microstructure and properties of the porous composite. Some of biomedical results are also discussed.

Zhang, X.↗

DOE OSTI2019

Microstructure Evolution and Mechanical Properties of Large-Scale AZ80 Magnesium Alloy Billets Produced by Multitemperature Multidirectional Forging

Grain refinement is an effective method to improve the mechanical properties of magnesium (Mg) alloys. In the present research, the combination of multidirectional forging (MDF) and forward extrusion for sizing with decreasing temperature pass by pass was employed to deform as-cast AZ80 magnesium alloy billet with large size to obtain fine grains and homogeneous microstructure. It was found that with the increasing number of MDF passes, the average grain size decreases; the homogeneity of microstructures and the percentages of dynamic recrystallised grains increase simultaneously. After six-pass MDF, fine and homogeneous microstructure with an average grain size of 15 μm was achieved; however, grain refinement became very difficult with a further increase in the MDF pass number. After eight-pass MDF plus forward extrusion for sizing, excellent mechanical properties of large-scale AZ80 magnesium alloy billet were obtained. The tensile strength, the yield strength and the elongation of billet are 410 MPa, 292 MPa and 14%, respectively. Furthermore, during multitemperature MDF, the inverse of the square root of grain size and tensile yield strength fit well with the Hall–Petch relationship.

36 MATERIALS SCIENCE↗