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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 901 records · Page 50
All sourcesNASA NTRSDOE OSTI
DOE OSTI2015

Enhance D. C. resistivity of Ba{sub 0.7}Sr{sub 0.3}TiO{sub 3} ceramic by acceptor (Mn) doping

In the present work, we prepared Ba{sub 0.7}Sr{sub 0.3}TiO{sub 3} and Mn (2 and 3 at % on Ti site) doped Ba{sub 0.7}Sr{sub 0.3}TiO{sub 3} ceramic by sol- gel method. The samples were characterized by X-ray diffraction (XRD). The XRD patterns reveled that Mn ions did not change the perovskite structure of BST (70/30). The dielectric measurements proved that dielectric constant decreased with Mn doping. The dc resistivity was studied by using I-V measurements. The dc resistivity of the BST increased with Mn doping, which suppressed the leakage current.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Structural and electrical properties of ferroelectric Na{sub 0.5} (Bi{sub 1-x}Pr{sub x} ){sub 0.5}TiO{sub 3} (x=0.00 and 0.10) ceramics synthesized by Sol-Gel method

Ferroelectric Na{sub 0.5}(Bi{sub 1-x}Pr{sub x}){sub 0.5}TiO{sub 3} (x=0.00, 0.10) ceramics have been synthesized through sol-gel method. The phase formation has been confirmed by X-ray diffraction analysis of ceramics annealed at 800°C. The relaxation mechanism is observed from variation of dielectric constant with respect to temperature and frequency. Substitution of Pr reduces vacancies and defects identified from leakage current measurements. Further, the polarization Vs electric field (P-E) measurements have been performed at room temperature.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2016

Raman effect, structural and dielectric properties of sol-gel synthesized polycrystalline GaFe{sub 1-x}Zr{sub x}O{sub 3} (0≤x≤0.15)

Polycrystalline ceramic samples of Zirconium (Zr)-doped GaFeO{sub 3} (GaFe{sub 1-x}Zr{sub x}O{sub 3}) were studied using powder X-ray diffraction, complex impedance spectroscopy and Raman spectroscopic measurements to understand the effect of Zr doping on the structural and dielectric properties. The samples with varying Zr content were prepared by Sol-Gel method. X-ray data analysis confirmed the formation of single phase material without formation of any secondary phases and all are crystallized in Pc2{sub 1}n orthorhombic symmetry. Rietveld refinement of the X-ray data suggested an increase in the lattice constants due to size effect and decreases on x = 0.15 due to the effect of change in interplanner spacing. Impedance studies on the samples showed that the dielectric constant increases while loss tangent decrease as the Zr content increases. Raman scattering on GaFe{sub 1-x}Zr{sub x}O{sub 3} (x = 0, 0.05, 0.10, & 0.15) used to understand the composition dependence on phonon modes at room temperature. On Zr doping, Raman modes frequencies shifts to lower energies consistent with the X-ray data.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2021

Tuning Surface Stoichiometry of SOFC Electrodes at the Molecular and Nano-scale for Enhanced Performance and Durability

This project achieved the following objectives. Different cation segregation behaviors of different common SOFC cathodes, including La 0.6 Sr 0.4 Co0.2Fe 0.8 O 3-δ (LSCF), Sr 0.5 Sm 0.5 O 3-δ (SSC), and PrBa 0.5 Sr 0.5 Co 1.5 Fe 0.5 O5 +δ (PBSCF), were determined. We showed how oxygen partial pressure and gas impurities impact the stability of SOFC cathodes. We developed atomic layer deposition (ALD) coating techniques for electrodes and showed that by introducing different elements and different ALD oxidizers, electrode surface chemistry can be altered, resulting in enhanced oxygen reduction kinetics. In addition, we developed solution infiltration technique to enhance performance and durability of electrodes. Different infiltrates as well as different thermal treatment processes were screened to identify the optimal surface modification process that yields both low impedance and high durability. The modified cathode shows excellent stability and has a low area specific resistance (ASR) of only 0.2 Ωcm 2 at 600 °C after over 2000 hours of operation. Further, we developed ceramic anodes, SrFe(Co,Mo)O 3 (SFCM) and SrFe(Ni,Mo)O 3 (SFNM), and enhanced anode oxidation kinetics by solution infiltration or in situ catalyst exsolution from the ceramic anode surface. The modified anodes showed improved performance in full SOFCs, and the optimized anode modification shows high stability for over 400 hours at 550 °C. Moreover, the modified anode also demonstrates high durability in methane. This work provides fundamental understanding of electrode surface chemistry and demonstrates a simple, facile, cost-effective approach to enhance catalytic activity and durability of SOFC electrodes.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2023

Active metal catalyst

A method of forming a catalyst is provided herein. The method comprises combining a binder, a support, and an active metal to form a slurry composition. The method further comprises applying the slurry composition using an additive manufacturing process to form a green part. The method further comprises exposing the green part to heat at a temperature of from about 10° C. to about 150° C. to form the hardened part. The method further comprises applying a ceramic-based coating material to the hardened part to form the catalyst.

Zhao, Xianhui↗
DOE OSTI2016

Investigation of the Deposition and Densification Parameters on the Mechanical Properties of Pressurized Spray Deposited (PSD) 3-D Printed Ceramic Components

Oak Ridge National Laboratory (ORNL) and HotEnd Works teamed to investigate the use of pressurized spray deposition (PSD) technology for the production of ceramic parts via additive manufacturing. Scanning electron microscopy of sintered parts provided by HotEnd Works revealed voids large enough to compromise the mechanical properties of PSD manufactured parts. Scanning electron microscopy and particle size analysis of the alumina oxide powder feedstocks indicated that the powders contained some large particles and some agglomerations in the powder. Further classification of the powder feedstocks and removal of the agglomerates by sonication in the liquid used for the PSD process are recommended. Analysis of sintered parts indicated that the sonic modulus for the alumina part is consistent with other known values for alumina. The density for this part was determined by standard Archimedes immersion density methods and was found to be > 99.7 % of the theoretical density for pure alumina.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Direct Ab Initio Simulation of the Synthesis of BaZrO 3 and the Microstructure Impacts on Proton Transport

Controlling and predicting the processing-structure-performance relationship in functional materials is a grand challenge in materials science, with important implications for a wide range of emerging applications; a high fidelity understanding of the performance impact of microstructures formed under synthesis conditions is required to develop advanced materials, such as solid-state fuel cells and electrolyzers. Using the ceramic BaZrO 3 as a case study, we directly simulate the synthesis and investigate how proton transport is dictated by microstructures. We develop a framework that couples density functional theory (DFT), machine-learning interatomic potential (MLIP) driven molecular dynamics, and grand canonical Monte Carlo to perform large-scale, microstructure-resolved, atomistic simulations of proton transport in experimentally representative polycrystalline structures. Our fully ab initio approach, using a MLIP as a proxy for DFT, allows us to quantify the competition between two distinct diffusion mechanisms: one associated with grain-boundary regions and another within grains. When the impacts of grain boundaries are taken into account, proton transport exhibits substantial deviation from the bulk oxide limit. This addresses long-standing discrepancies between theory and experiments. Our integrated approach provides atomistic insight into microstructure-dependent proton pathways in BaZrO 3 and establishes a general protocol for predicting processing-structure-performance relationships.

organic↗
DOE OSTI2018

3-D Unsteady Model for Be-Steam Reaction in Water-Cooled Ceramic Breeder Blanket

Here, the design of the water-cooled ceramic breeder (WCCB) blanket includes beryllium multiplier layers. At elevated temperature, beryllium reacts with steam in an exothermic reaction producing beryllium oxide and hydrogen. Such situation may occur in WCCB in the case of the rupture of one of the cooling pipes in the blanket module. This process occurs locally in a complex 3-D geometry of the blanket containing several different granular levels and a network of cooling pipes and structural supports. The process is also inherently unsteady since reaction rate depends on concentration of steam and pure beryllium which changes in time. In order to perform the detailed analysis of the process, the model of the reacting flowthrough porous media was developed and introduced into 3-D computational fluid dynamics code. In this model, granular beds are introduced as porous solids simplifying the model geometry and reducing typical mesh size to manageable amount of tens of millions of elements. A reaction rate between solid beryllium and steam is obtained from experimental results, and depends on temperature and concentration of the reactants. The differential equation for beryllium oxide fraction is introduced, allowing obtaining distributions of beryllium oxide in space and time. Multicomponent flow consisting of a homogenous mixture of steam and hydrogen is considered flowing through the porous solid with variable properties. Sink and source terms for steam and hydrogen fractions are determined by local beryllium oxide mass fraction source according to the molar ratios of beryllium steam reaction. The conjugated heat transfer approach is applied to calculate heat transfer in support structures as well as coolant flow, simultaneously with the porous medium steam flow in a blanket's granular beds. The model is validated using experimental data on beryllium steam reaction for granular bed samples.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2017

Ab initio molecular dynamics simulations of low energy recoil events in MgO

In this paper, low-energy recoil events in MgO are studied using ab initio molecular dynamics simulations to reveal the dynamic displacement processes and final defect configurations. Threshold displacement energies, E d , are obtained for Mg and O along three low-index crystallographic directions, [100], [110], and [111]. The minimum values for E d are found along the [110] direction consisting of the same element, either Mg or O atoms. Minimum threshold values of 29.5 eV for Mg and 25.5 eV for O, respectively, are suggested from the calculations. For other directions, the threshold energies are considerably higher, 65.5 and 150.0 eV for O along [111] and [100], and 122.5 eV for Mg along both [111] and [100] directions, respectively. These results show that the recoil events in MgO are partial-charge transfer assisted processes where the charge transfer plays an important role. Finally, there is a similar trend found in other oxide materials, where the threshold displacement energy correlates linearly with the peak partial-charge transfer, suggesting this behavior might be universal in ceramic oxides.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Trace Impurities Identified as Forensic Signatures in CMX-5 Fuel Pellets Using X-ray Spectroscopic Techniques

We report that small-particle analysis is a highly promising emerging forensic tool for analysis of interdicted special nuclear materials. Integration of microstructural, morphological, compositional, and molecular impurity signatures could provide significant advancements in forensic capabilities. We have applied rapid, high-sensitivity, hard X-ray synchrotron chemical imaging to analyze impurity signatures in two differently fabricated fuel pellets from the 5th Collaborative Materials Exercise (CMX5) of the IAEA Nuclear Forensics International Working Group. The spatial distributions, chemical compositions, and morphological and molecular characteristics of impurities were evaluated using X-ray absorption near-edge structure (XANES) and X-ray fluorescence chemical imaging to discover principal impurities, their granularity, particle sizes, modes of occurrence (distinct grains vs incorporation in the UO 2 lattice), and sources and mechanisms of incorporation. Differences in UO 2+x stoichiometry were detected at the microscale in nominally identical UO 2 ceramics (CMX5-A and CMX5-B), implying the presence of multiple UO 2 host phases with characteristic microstructures and feedstock compositions. Al, Fe, Ni, W, and Zr impurities and integrated impurity signature analysis identified distinctly different pellet synthesis and processing methods. For example, two different Al, W, and Zr populations in the CMX5-B sample indicated a more complex processing history than the CMX5-A sample. K-edge XANES measurements reveal both metallic and oxide forms of Fe and Ni but with different proportions between each sample. Altogether, these observations suggest multiple sources of impurities, including fabrication (e.g., force-sieving) and feedstock (mineral oxides). This study demonstrates the potential of synchrotron techniques to integrate different signatures across length scales (angstrom to micrometer) to detect and differentiate between contrasting UO 2 fuel fabrication techniques.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2014

Softening of antiferroelectricity in PbZrO{sub 3}-Pb(Mn{sub 1/2}W{sub 1/2})O{sub 3} complex perovskite solid solution

A new solid solution of complex perovksite structure, (1-x)PbZrO{sub 3}-xPb(Mn{sub 1/2}W{sub 1/2})O{sub 3} (PZ-xPMnW, with x = 0–0.1), is prepared by solid state reaction method. Its crystal structure, dielectric properties, and antiferroelectricity are investigated. It is found that the crystal structure of the solid solution remains in the orthorhombic Pbam symmetry with x ≤ 0.1. The induced ferroelectric polarization (P{sub Ind}) is enhanced, whereas the critical field (E{sub Cr}) is decreased, with increasing PMnW concentration, indicating the softening of antiferroelectricity in PZ. The Curie temperature (T{sub C}) is also decreased with the substitution of PMnW for PZ. The grain size is significantly enlarged, which could be attributed to the presence of a transient liquid phase during the sintering process. Measurements of the magnetization by means of SQUID confirm that the Mn ion exists in a high spin state with a 2+ oxidation state. The softening of antiferroelectric order and the improvement in induced polarization make the PZ-PMnW ceramics an interesting material system for such applications as energy storage devices.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2019

Phase separation and crystallization of complex borosilicate melts for glass-ceramic waste forms

Waste loadings of reprocessed spent nuclear fuel vitrified into borosilicate glass can be increased by precipitating environmentally stable phases concentrated with waste components in a chemically stable glass matrix. The principal objective of this study was to characterize the development of crystalline powellite (CaMoO 4 and related phases) and oxyapatite (Ca 2 LN 8 Si 6 O 26 ) in borosilicate glass-ceramics and to determine how the formation of those phases affected its chemical durability. Borosilicate glasses provided by PNNL were re-melted and quenched at rates from over 300°C/s to ~0.05°C/s. Isothermal heat treatment experiments were conducted by quenching melts in a molten tin bath at various temperatures, holding for periods of time, and then quenching in a water bath. Analytical electron microscopy and x-ray diffraction provided information about the kinetics of the phase separation and crystallization processes responsible for microstructural development. Powellite and oxyapatite crystals formed during slower quench rates and longer isothermal times, and time-temperature-transformation (TTT) diagrams were developed from the latter experiments. A hot thermocouple test (HTT) system was built to rapidly quench melts and hold them at set times to provide supplementary TTT information, but that system was not as sensitive to the phase transformations as other tests. Corrosion tests were performed to understand how the individual phases in the glass-ceramic affect its overall chemical durability. Product consistency tests, performed at Missouri S&T and at Savannah River National Lab, provided release rates of major elements from samples as a function of cooling rate, and atomic force microscopy and profilometry measurements of surface topology determined the relative corrosion rates of the residual glass and oxyapatite phases. Faster dissolution rates were measured from samples cooled more slowly and these were explained by the greater fractions of B 2 O 3 in the residual glass phase after the formation of oxyapatite and powellite. Oxyapatite was found to be more durable than the residual glass.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2017

High temperature ceramic heat exchanger for solid oxide fuel cell

A ceramic heat exchanger with high effectiveness and low-pressure drop has been developed for application as a cathode air preheater for a Solid Oxide Fuel Cell (SOFC). At the operating conditions of SOFCs, typical metallic alloys as those used in commercial heat exchangers may undergo chromium volatilization, which is a known cathode degradation mechanism that reduces SOFC performance and life. Use of ceramics such as alumina or alumina-silicate instead of chromium-containing metal is one approach to eliminate the effects of chromium on the SOFC cathode. This project leverages the geometric design of a heat exchanger previously prototyped and tested [1] to fabricate a novel heat exchanger made from a ceramic material. All calculations of heat exchanger performance requirements are based on state of the art SOFC operating conditions. The alumina-silicate material selected to fabricate the modular prototype heat exchanger was made via a heat transfer based trade-off analysis that shows that for low pressure-drop devices, flow convection is the limiting heat transfer mechanism, and therefore wall conductivity becomes less relevant to heat transfer effectiveness. The modular design presented allows for incremental aggregation of modules to target a broad range of operating conditions typical of present and upcoming SOFC applications (e.g., 25 to 400 kWe). The completed prototype was subjected to a series of static leak/pressure tests, dynamic pressure drop tests both at ambient and realistic service temperature conditions, and finally to a matrix of heat transfer experiments to fully characterize its heat transfer effectiveness (including tests at hot gas temperatures up to 1033 K or 1400oF). The stand-alone system was demonstrated in the laboratory to successfully satisfy the design criteria at realistic operating conditions, showing a total pressure drop at the design flow of 8 g/sec of 6 kPa (vs. 3.45 kPa approximate requirement). It was also shown to have heat transfer effectiveness of 76% (with 73% being the design requirement). Moreover, the unit was shown to operate leak-free, and the ceramic elements and seals were capable of withstanding the thermal cycling resulting from the testing procedure. The heat exchanger was then integrated into a modified fuel cell test stand and tested at steady state operation. Unfortunately, the level of performance achieved was lower than expected based on laboratory performance tests. This appears to have been the result of an unforeseen loosening of a heat exchanger structural component, which resulted into a leak that prevented proper supply of hot gas to the heat exchanger. However, in general terms, the heat exchanger/fuel cell integration process provides confidence that a future application of the unit with a SOFC is feasible, assuming structural issues are addressed. It is considered that the difficulties encountered at the last stage of the program provided invaluable input in locating shortcomings of the mechanical design and integration approach. A portion of this work was presented at the ASME Power & Energy Conference, in Charlotte, NC, on June 28th 2016 in a paper entitled “Development of a Ceramic Heat Exchanger for Application as Solid Oxide Fuel Cell Cathode Air Preheater” and the corresponding paper was published in the Proceedings of the ASME 2016 Power & Energy Conference, Paper No.: PowerEnergy2016-59333 [8].

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2024

Combustion Synthesis of Transuranic-doped Ceramics for Nuclear Waste Immobilization

Utilizing the devised SCS technique, crystalline transuranic-doped zirconate pyrochlores were formed for the first time without the need for a subsequent heating step. Typically, materials rapidly synthesized in a single-step self-sustaining exothermic reaction require further heating to induce crystallization and purify the product. The need for this secondary processing step can be attributed to factors such as an improper oxidizer to fuel ratio and the utilization of strong complexing compounds as fuels (i.e., reducing agents), all of which hinder complete combustion. The efficacy of the developed process was demonstrated by fabricating crystalline plutonium-doped Gd2Zr2O7 from solutions containing metal nitrates and urea in a properly tuned ratio

Burton-Allen, Janiya D.↗
DOE OSTI2017

Pressure Induced Phase Transformations in Ceramics

The study of materials with unusual properties offers new insight into structure-property relations as well as promise for the design of novel composites. In this spirit, the PIs seek to (1) understand fundamental mechanical phenomena in ceramics that exhibit pressure-induced phase transitions, negative coefficient of thermal expansion (CTE), and negative compressibility, and (2) explore the effect of these phenomena on the mechanical behavior of composites designed with such ceramics. The broad and long-term goal is to learn how to utilize these unusual behaviors to obtain desired mechanical responses. While the results are expected to be widely applicable to many ceramics, most of the present focus is on silicates, as they exhibit remarkable diversity in structure and properties. Eucryptite, a lithium aluminum silicate (LiAlSiO 4 ), is specifically targeted because it exhibits a pressure-induced phase transition at a sufficiently low pressure to be accessible during conventional materials processing. Thus, composites with eucryptite may be designed to exhibit a novel type of transformation toughening. The PIs have performed a combination of activities that encompass synthesis and processing to control structures, atomistic modeling to predict and understand structures, and characterization to study mechanical behavior. Several materials behavior discoveries were made. It was discovered that small amounts of Zn (as small as 0.1 percent by mol) reverse the sign of the coefficient of thermal expansion of beta-eucryptite from negative to slightly positive. The presence of Zn also significantly mitigates microcracking that occurs during thermal cycling of eucryptite. It is hypothesized that Zn disrupts the Li ordering in beta-eucryptite, thereby altering the thermal expansion behavior. A nanoindentation technique developed to characterize incipient plasticity was applied to examine the initial stages of the pressure induced phase transformation from beta to epsilon-eucryptite and show that the transformation nucleation is related to the motion of the tetrahedral units making up the structure. It was revealed that the conduction of Li ions through the structure is also dictated by the tetrahedral unit arrangement and how their positions change with temperature. The critical pressure to obtain the high pressure phase of eucryptite was shown to depend on the grain size. The structure of the high pressure phase was determined with a combination of atomistic modeling and in situ x-ray diffraction experiments.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Nanoporous Hybrid Electrolytes for High-Energy Batteries Based on Reactive Metal Anodes

Successful strategies for stabilizing electrodeposition of reactive metals, including lithium, sodium, and aluminum are a requirement for safe, high-energy electrochemical storage technologies that utilize these metals as anodes. Unstable deposition produces high-surface area dendritic structures at the anode/electrolyte interface, which causes premature cell failure by complex physical and chemical processes that have presented formidable barriers to progress. In this work, it is reported that hybrid electrolytes created by infusing conventional liquid electrolytes into nanoporous membranes provide exceptional ability to stabilize Li. Electrochemical cells based on γ-Al 2 O 3 ceramics with pore diameters below a cut-off value above 200 nm exhibit long-term stability even at a current density of 3 mA cm -2 . The effect is not limited to ceramics; similar large enhancements in stability are observed for polypropylene membranes with less monodisperse pores below 450 nm. These results are critically assessed using theories for ion rectification and electrodeposition reactions in porous solids and show that the source of stable electrodeposition in nanoporous electrolytes is fundamental.

25 ENERGY STORAGE↗
DOE OSTI2019

Laser ablation of polymers: a review

Laser ablation (LA), which employs a pulsed laser to remove materials from a substrate for generating micro-/nanostructures, has tremendous applications in the fabrication of metals, ceramics, glasses and polymers. It has become a noteworthy approach for achieving various functional structures in engineering, chemistry, biology, medicine and other fields. Polymers are one such class of materials; they can be melted and vaporized at high temperature during the ablation process. A number of polymers have been researched as candidate substrates in LA, and many different structures and patterns have been realized by this method. The current states of research and progress are reviewed from basic concepts to optimal parameters, polymer types and applications. Additionally, the significance of this paper is to provide a basis for follow-up research that leads to the development of superior materials and high-quality production through LA. In this review, we first introduce the basic concept of LA, including mechanism, laser types (millisecond, microsecond, nanosecond, picosecond and femtosecond) and influential parameters (wavelength, repetition rate, fluence and pulse duration). Then, we focus on several commonly used polymer materials and compare them in detail, including the effects of polymer properties, laser parameters and feature designs. Finally, we summarize the applications of various structures fabricated by LA in a variety of areas along with a perspective of the challenges in this research area. Overall, a thorough review of LA of several polymers is presented, which could pave the way for characterization of future novel materials.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Microstructural variation through weld thickness and mechanical properties of peened friction stir welded 6061 aluminum alloy joints

The current study examined the effect of microstructure variation on the development of mechanical properties in friction stir welded joints of 6061-T6 aluminum alloy, which were subsequently processed by shot peening (SP). Following to FSW, fatigue specimens were extracted perpendicularly to the welding direction. Surface Skimming to 0.5 mm from crown and root sides of the joint was made and SP was later applied on the two sides using ceramic shots of two different Almen intensities of 0.18 mmA and 0.24 mmA. Microstructural examination by electron back scattered diffraction (EBSD) indicated variation in the grain refinement of the weld zone, with coarsest grains (5 μm) at the crown side and finest grains (2 μm) at the root side. Reduction of microhardness to 60 HV occurred in the weld zone for samples in FSW condition. Application of SP promoted significant strain hardening at the crown side, with Almen intensities of 0.24 mmA providing maximum increase in microhardness to 120 HV. On the contrary, only a maximum microhardness of 75 HV was obtained at the root side. The difference in strain hardening capability at the two sides was strongly dependent on grain size. The two Almen intensities produced similar distribution of compressive residual stresses in the subsurface regions that led to enhance the fatigue strength to the level of base metal for N ≥ 10{sup 5} cycles. Yet, the increase in fatigue strength was more pronounced with increasing Almen intensity to 0.24 mmA, demonstrating further enhancement by strain hardening. - Highlights: • Grain refinement was observed after friction stir welding of AA 6061-T6. • Reduction in microhardness and fatigue strength were obtained after welding. • Variation in grain refinement led to different hardening behavior after peening. • Shot peening induced beneficial compressive residual stresses. • Shot peening and surface skimming markedly improved the fatigue performance.

36 MATERIALS SCIENCE↗