Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Microstructure”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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

At least 919 records · Page 51
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Effect of Preheated Microstructure Vis-à-vis Process Parameters and Characterization of Orange Peel in Incremental Forming of AA1050 Sheets

The present investigation systematically analyzes and compares the influence of microstructure and crystallographic texture of AA1050 sheet to that of the most critical process parameters, namely tool dimension, and incremental step depth, in single-point incremental forming (SPIF) process. The sheet samples were preheated at different temperatures to reform the original, i.e., distorted and misoriented grain distribution. The results from experimental and statistical analyses report higher sensitivity of global spring back, surface topography and forming limits strains to variations in microstructure and texture than tool diameter and incremental step depth. The preheating of the sheets resulted in the formation of preferential texture by grain reformation, which leads to the increase in the fraction of homogeneous orientated grains. Such grains increase the maximum forming limit strains and reduce the global spring back in SPIF. Fractography analysis of the failed components revealed that improvement in formability due to grain homogenization (developed texture) may be attributed to larger average void diameter. Empirical models were also developed, and optimized levels of parameters were identified to maximize the efficiency of the SPIF process. Further, qualitative and quantitative characterization of orange peel roughness was carried out by segregating the external formed surface into surfaces subjected to orange peel roughness and tool-induced texture.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effects of Laser Fluence on Microstructure and Bonding Characteristics of Wideband Laser-Deposited Nickel Composite Coatings

The wideband laser has shown great potential in metal–ceramic coatings deposition due to the high efficiency and low dilution rate. However, the effects of wideband laser process on microstructure evolution and bonding mechanism at the coatings/substrate interface are still a critical problem and need further investigation. In this work, nickel composite coatings are fabricated on the surface high-strength low-alloy steel. The effects of laser fluence on microstructure evolution, shear strength and fracture mechanism are studied. Results indicated the added WC particles were partly dissolved due to the high-power laser irradiation. Many block precipitates and dense eutectic were synthesized in composite coatings. Reinforced phases mainly consist of Cr{sub 5}B{sub 3}, Cr{sub 23}C{sub 6}, W{sub 2}C and Cr{sub 3}Ni{sub 2}. The dilution of Q550 steel contributed to the formation of nickel dendrites and facilitated a dense metallurgical bonding at coating/substrate interface when laser fluence was high. Shear strength tests indicated the laser fluence and shear strength had a positive correlation. For Ni60/WC composite coatings designed in these experiments, the recommend laser fluence should be higher than 55 J/mm{sup 2}, above which the shear strength could be greater than 200 MPa. Fracture surfaces indicated the failure mechanism of composite coatings was quasi-cleavage fracture.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Dual-Phase Heat Treatment on Microstructure and Mechanical Properties of S135 High-Strength Drill Pipe Steel

Effect of dual-phase heat treatment (DPHT) on microstructure and mechanical properties of S135 high-strength drill pipe steel was studied by means of optical microscope, scanning electron microscope and mechanical property testing. The results show that the ferrite–martensite dual-phase microstructures were obtained at 760-800 °C. With increase in DPHT temperature, the volume fraction of martensite increases and the ferrite decreases. When the DPHT temperature is low, martensite is distributed as an island on the ferrite matrix, and ferrite is distributed as an island on the martensite matrix when the DPHT temperature is high. The hardness and strength of the steel increase, the plasticity and toughness decrease, the steel changes from ductile fracture to brittle fracture and the micro-fracture morphology changes from dimple to cleavage with increase in DPHT temperature. The strain hardening exponent of the as-received steel shows one ‘n’ value, but exhibits two ‘n’ values after DPHT. When the DPHT temperature is 750 °C, the relative content of martensite in the duplex structure is 15-20%, and the impact energy of the steel is similar to that of the as-received S135 drill pipe steel, and the strength is increased by about 15%. Micropores and micro-cracks on the subsurface of tensile fracture surface are mainly formed at the martensite/ferrite phase boundary or in the martensite slit.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Room-Temperature Microstructural Evolution of Extruded AM80 Magnesium Alloys under Dynamic Loading

Dynamic compression tests were conducted using a split Hopkinson pressure bar along the transverse direction at strain rates (SRs) of 3200 and 6000 s{sup −1}. The initial microstructure significantly affected the flow stress behavior and microstructural evolution of the two studied AM80 magnesium alloys. Under the same SR loading, the as-extruded alloy exhibited an apparently higher flow stress. At a SR of 6000 s{sup −1}, the flow stress of the as-extruded alloy exhibited a visible decrease (~ 34 MPa) as the strain increased to ~ 0.2, whereas a constant flow stress was exhibited by the solution-treated alloy. High-density dislocations and mechanical twins were detected in the two alloys at a SR of 3200 s{sup −1}. Interestingly, dynamic recrystallization (DRX) with an average grain size of ~ 2 µm was only identified in the as-extruded alloy as the applied SR increased to 6000 s{sup −1}. The increased localized deformation in the as-extruded alloy due to the retained strain energy and high critical twinning stress improved the DRX driving force, thereby resulting in visibly different micrographs of the two alloys when impacted at the SR of 6000 s{sup −1}.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Cobalt on the Microstructure and Corrosion Behavior of Martensitic Age-Hardened Stainless Steel

To evaluate the influence of cobalt on the microstructure and pitting behavior of martensitic age-hardened stainless steel (MASS), the microstructures and electrochemical behaviors were characterized by optical microscopy, scanning electron microscopy, transmission electron microscopy, x-ray photoelectron spectroscopy, potentiodynamic curve, electrochemical impedance spectroscopy, and Mott–Schottky analysis. Results indicated that adding cobalt reduced the grain size of the original austenite, refined the lath martensite, inhibited the precipitation of Cu-rich phases, and increased the content of reversed austenite. Compared with the cobalt-free steel, the cobalt-containing steel has a higher pitting potential, lower corrosion current density, and higher pitting resistance. The primary components of the passive film grown on the cobalt-free steel included (Cr, Fe) oxides, such as Cr{sub 2}O{sub 3}, Cr(OH){sub 3}, FeOOH, and Fe{sub 2}O{sub 3}. The cobalt-containing steel included the aforementioned components as well as Co, which was attributed to the formation of the passive film in the forms of CoFe{sub 2}O{sub 4}, Co(OH){sub 2}, and CoO. In addition, the synergy of the refined lath martensite and the precipitation of the Cu-rich phase induced an increase in corrosion resistance in MASS containing cobalt.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Microstructural Characteristics and Mechanical Properties of Friction-Stir-Welded CuSn6 Tin Bronze

Tin bronze is widely applied in various industries for its excellent wear and corrosion resistance. Friction stir welding is a solid-state welding process, which generates less heat and avoids the melting-related defects. CuSn6 tin bronze plates of 4 mm in thickness were friction-stir-welded at welding speeds ranging from 50 to 150 mm/min under a constant rotation speed. The microstructural and mechanical properties of joints were investigated. The microstructure of the stir zone consists of refined equiaxed grains. The grain size decreased from top to bottom of the welds. The mean grain size is increased with increasing welding speed. The largest strength and elongation of welded joints were both obtained at the welding speed of 100 mm/min. During tensile test, all of the joints were fractured at the heat affected zone of retreating side with typical plastic fracture feature, since the grains were coarsened by welding heat.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Microstructure Refinement on Hardness Homogeneity of Aluminum Alloy 1100 Processed by Accumulative Roll Bonding

This work examines the effect of grain refinement via accumulative roll bonding (ARB) on the homogeneity of microstructure and hardness through the thickness of commercially pure aluminum AA1100 sheets. The use of 7 cycles of ARB was shown to produce homogeneous ultrafine-grained microstructure, reducing the grain size to 0.46 and 1.03 µm in normal direction and rolling direction, respectively. Examination by electron backscattered diffraction indicates that continuous dynamic recrystallization was the main mechanism for the formation of submicron equiaxed grains bounded with high-angle grain boundaries (HAGBs). The fraction of HAGBs increased gradually reaching a maximum of 71.6% after 7 cycles. Through-thickness hardness measurements using Vickers and nanoindentation tests show an increase from 43.5 Hv (0.85 GPa) for as-received sample to 63 Hv (1.1 GPa) after 7 cycles. The heterogeneity in hardness through the thickness of the as-received material was shown to restrain the evolution of uniform hardness across the sheet thickness with increasing ARB cycles. Tensile tests showed that the tensile strength is increased to 250 MPa, which is about 2 times its initial value. Owing to the high stacking fault energy of AA1100, strong dynamic recovery occurred with increasing ARB strain which was balanced with the strain hardening property of the material. This resulted in plastic instability at small strains and thus early necking during the tensile test.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Y{sub 2}O{sub 3} Addition on the Microstructure, Wear Resistance, and Corrosion Behavior of W-4.9Ni-2.1Fe Heavy Alloy

Binding and particle phases are the two important parameters influencing materials properties. In this study, a series of novel W-4.9Ni-2.1Fe-xY{sub 2}O{sub 3} (in weight%) alloys with different Y{sub 2}O{sub 3} contents are prepared by secondary ball milling and spark plasma sintering (SPS) techniques to obtain uniformly distributed γ-(Ni, Fe) binding phases and finer grains. The microstructure, mechanical, wear resistance, and corrosion behavior of the sintered bodies with different Y{sub 2}O{sub 3} were obtained by x-ray diffraction, scanning electron microscopy, Rockwell hardness tester, friction wear tester, and three-dimensional profile instruments. The results showed that a certain addition of Y{sub 2}O{sub 3} led to refined grains and uniformed microstructures; but, if excessive, a weak grain refinement would be appeared. Moreover, the grain size tends to be stable with enhancing of the Y{sub 2}O{sub 3} content. Considering properties such as density, hardness, compression yield strength, grain size, and uniform distribution of tungsten hard phase and γ-(Ni, Fe) binding phase, the comprehensive optimal amount of 0.7 wt.% of Y{sub 2}O{sub 3} was attained for the alloy. Meanwhile, the SPS sintered body also exhibited the best friction, wear behavior, and corrosion resistance in 3.5% of NaCl solution.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Heat Treatment on Microstructure and Mechanical Properties of Ti-6Al-4V-1.5Mn Fabricated by Powder Metallurgy

Ti-6Al-4V-1.5Mn alloy was prepared by powder metallurgy and solid solution aging treatment. Effect of composition segregation on properties of the titanium alloy was eliminated, and microstructure and the mechanical properties of the alloy were studied. Results show that the microstructure of Ti-6Al-4V-1.5Mn is composed of homogeneous α + β phase, and the optimal mechanical properties of the alloy are obtained when the solution temperature is 950 °C and the aging temperature is 460 °C. Analysis of the fracture illustrates that a small amount of dimple was found in the section and the fracture of the material was quasi-cleavage fracture.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Combined Torsion and Tension on the Microstructure and Fracture Behavior of 316L Austenitic Stainless Steel

In this study, the microstructure evolution and fracture behavior of 316L austenitic stainless steel (ASS) deformed by torsion–tension at room temperature was systematically investigated. During combined tension and torsion, the grain size was refined with increasing shear strain. In addition, the microtexture exhibited a preferred orientation with increasing shear stress. The metastable austenite underwent phase transition when the shear stress increased. The shear stress affected the fracture morphology, and dimples with different sizes and depths were observed for different pre-torsions. The dislocation density increased significantly owing to severe shear deformation. In addition, the dislocation structure evolved and subgrains appeared with the accumulation of shear strain during this combined deformation. The result showed that pre-torsion deformation plays an important role in improving the comprehensive performance and controlling the microstructure evolution of the sample subjected to tension deformation.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Deformation Behavior and Microstructural Evolution of Reeled Pipeline Steels during Cyclic Plastic Deformation

API X60 steel used for reeled pipeline was subjected to different amounts of cyclic plastic deformation (CPD) by multiple tension–compression tests in order to study the deformation behavior and microstructural evolution during each stage of reel-lay installation process. It was found that the yield strength was significantly reduced by about 110 MPa during the first CPD cycle due to the Bauschinger effect. However, the yield strength was little affected by the subsequent CPD cycles, and the yield strength difference between tension and compression tended to reach a steady-state value of 23 MPa after multiple CPD cycles. With the increase in CPD cycles, the proportion of low-angle grain boundaries declined from 50.9 to 35.7%, and the CPD contributed to the formation of immovable dislocation walls and cells due to the dislocation rearrangement, causing the stable yield strength. The CPD process with strain level of 3% had no prominent effect on the tensile strength and elongation, because the change in microstructures was not enough to alter the work hardening completely after multiple CPD cycles.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Microstructure Evolution and Mechanical Properties of the AZ91 Magnesium Alloy with Sr and Ti Additions in the As-Cast and As-Aged Conditions

Effect of different amounts of Sr and Ti additions with T6 heat treatment on microstructure and mechanical properties of the AZ91 alloy was investigated. The microstructure of the AZ91 alloy is consisted of the α-Mg phase surrounded by the semicontinuous network of β-Mg{sub 17}Al{sub 12} intermetallics. The average grain size and volume fraction of β phase decreased up to 1 wt.% Sr and 0.1 wt.% Ti additions. Exceeding Ti additions led to increase in both grain size and volume fraction. It was found that the grain refinement mechanism of AZ91 alloys with Sr additions was grain restriction factor. Also, 0.1 wt.% Ti addition could refine the grain structure of the AZ91 alloy by the formation of Al{sub 3}Ti particles that act as nucleation sites for the α-Mg phase. Furthermore, adding 1 wt.% Sr and 0.1 wt.% Ti enhanced the hardness values for both cast and aged AZ91 alloy. Moreover, ultimate tensile strength and tensile elongation values reached their maximum amounts with the 0.5 wt.% Sr and 0.1 wt.% Ti additions and more Sr and Ti additions deteriorated the mechanical properties of cast and aged AZ91 alloys. The fracture surface characterizations had good relations with the tensile properties. The fracture modes were cleavage and quasi-cleavage in the cast and aged AZ91 alloys. Furthermore, the optimum levels of Sr and Ti additions altered the fracture modes to more quasi-cleavage fractures.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Electropulsing on Surface Mechanical Behavior and Microstructural Evolution of Inconel 718 during Ultrasonic Surface Rolling Process

In the current study, the surface mechanical behavior and microstructural evolution of Inconel 718 superalloy processed by the ultrasonic surface rolling process (USRP) and electropulsing-assisted ultrasonic surface rolling process (EP-USRP) were carefully analyzed. The experimental results suggested that after EP-USRP with a frequency of 400 Hz, significant enhancements in Vickers microhardness and nanoindentation hardness were achieved compared to those of USRP specimens, with increases of 13.6 and 9.9%, respectively. Moreover, the machined surface quality, wear resistance, and thermal stability were also improved after EP-USRP (400 Hz). These enhancements in mechanical behavior are closely related to the microstructural evolution induced by electropulsing. Under the coupling of thermal and athermal effects of high-energy electropulsing, the deformation limit of USRP is surpassed and a new balance is achieved between the electropulsing softening effect and the ultrasonic rolling hardening effect. Therefore, further grain refinement, improved plastic deformation ability in the strengthened layer, and the interaction effect between nano-sized precipitates and grain boundaries are probably the main reasons for these results.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Discontinuous Precipitation in U-10 wt.%Mo Alloy: Reaction Kinetics, Effect of Prior gamma-UMo Microstructure, the Role of Grain-Boundary Misorientation, and the Effect of Ternary Alloying Addition

Eutectoid transformation in U-10 wt.% Mo (U10Mo) alloy initiates through discontinuous precipitation (DP) resulting in the formation of a lamellar microstructure that consists of an a-U and Mo-enriched bcc ?-UMo phase along the prior ?-UMo grain boundaries. DP is the main mode of transformation at 500°C. However, continuous precipitation (CP) of ?’ U2Mo phase together with grain-boundary DP is observed at 400°C. The reaction kinetics are noted to be very sluggish at 400°C compared to 500°C. The degree of eutectoid transformation is related to the prior ?-UMo grain size, and a smaller average grain size leads to a larger amount of transformation at a given reaction temperature. Minor addition (0.2 wt.%) of a third alloying element (Cr, Ni, Co) leads to significant changes in the nature of the DP mechanism in U10Mo alloy. In addition, high-angle grain boundaries with a misorientation of 30–45° are observed to be the major DP initiation sites. The microstructural evolution of U10Mo alloy with regard to DP-based reaction is discussed.

Jana, Saumyadeep↗
DOE OSTI2021

Adoption of image-driven machine learning for microstructure characterization and materials design: A Perspective

Microstructure characterization enables the development of structure-processing-property relationships critical to several research areas within the broad field of materials science, from alloy design to the assessment of corrosion resistance, and failure analysis. Conventional approaches to material characterization have relied on either qualitative inference by the human ex-pert or software applications that can extract high-level features from images, such as boundary segmentation, average grain diameter, etc. Such approaches rely heavily on subject matter expert user intervention and knowledge of what phases or more generally, what microstructural features, are of interest. The recent surge in the adoption of machine learning techniques to address problems in materials engineering has brought with it an increased interest and application of Image Driven Machine Learning (IDML) approaches. In this work, we review the applications of IDML to the field of materials characterization. A canonical hierarchy of stages is defined, which when put sequentially together completes an IDML study: problem definition, dataset building, model selection and training, model evaluation, and integration with existing instrumentation or simulation workflow. The studies reviewed in this work are analyzed from the perspective of each of these stages. Such a review permits agranular assessment of the field, for example the impact of IDML on materials characterization at the nanoscale, the size of a typical dataset required to train a semantic segmentation model on electron microscopy images, ubiquitousness of transfer learning in the domain, etc. Finally, we discuss the importance of interpretability and explainability in the field of IDML for materials characterization, and provide an overview of two emerging techniques in the field: semantic segmentation and generative adversarial networks.

Baskaran, Arun↗
DOE OSTI2024

Review of Solid State Consolidation Processing Techniques of ODS Steels (Hot Extrusion, Hot Isostatic Pressing, Spark Plasma Sintering, and Stir Friction Consolidation): Resulting Microstructures and Mechanical Properties

This paper reviews the solid-state consolidation processing techniques for Oxide Dispersion Strengthened steels and compares them in terms of the resulting microstructure and reported mechanical properties. Synthesis techniques include hot extrusion, hot isostatic pressing, spark plasma sintering and friction consolidation. The effects of process parameters on the resulting microstructures and performance are discussed for each technique. Average oxide size, average grain size, and porosity are compared across techniques, as well as mechanical strength and ductility. Across consolidation techniques where temperature can be controlled, a low sintering temperature with a high sintering pressure is favorable for keeping oxide sizes, grain sizes, and porosity low. The use of yttrium and titanium for oxide formation has been evidenced to reduce oxide sizes, and tungsten additions have been shown to improve strength. Current literature suggests that the more mature hot extrusion technique produces stronger steel with consistently fine oxides, while other alternative solid-state consolidation, while promising, offer margin for improvement.

36 MATERIALS SCIENCE↗
DOE OSTI2019

BisQue for 3D Materials Science in the Cloud: Microstructure–Property Linkages

Accelerating the design and development of new advanced materials is one of the priorities in modern materials science. These efforts are critically dependent on the development of comprehensive materials cyber-infrastructures which enable effcient data storage, management, sharing, and collaboration as well as integration of computational tools that help establish processing{structure{property relationships. In this contribution, we present implementation of such computational tools into a cloud-based platform called BisQue (Kvilekval et al., 2010). We first describe the current state of BisQue as an open-source platform for multidisciplinary research in the cloud and its potential for 3D materials science. We then demonstrate how new computational tools, primarily aimed at processing{structure{property relationships, can be implemented into the system. Speci cally, in this work, we develop a module for BisQue that enables microstructure-sensitive predictions of effective yield strength of two-phase materials. Towards this end, we present an implementation of a computationally effcient data-driven model into the BisQue platform. The new module is made available online and can be used from a web browser without any special software and with minimal computational requirements on the user end. The capabilities of the module for rapid property screening are demonstrated in case studies with two different methodologies based on datasets containing 3D microstructure information from (i) synthetic generation and (ii) sampling large 3D volumes obtained in experiments.

36 MATERIALS SCIENCE↗
DOE OSTI2025

An Integrated High-Speed Microstructural Characterization Method Using Simultaneous XRD, Stereo-DIC, and PCI

High-speed characterization of the deformation mechanisms in polycrystalline metals requires the quantification of full strain fields and local microstructural evolutions simultaneously. In this paper, we present a novel experimental method to integrate phase-contrast imaging (PCI), stereographic digital image correlation (stereo-DIC), and full-ring X-ray diffraction (XRD) to allow for the simultaneous characterization of polycrystalline metals at 1MHz or higher. A Kolsky bar was integrated into the synchrotron X-ray source in Sector 32 ID-B at the Advance Photon Source (APS) at Argonne National Laboratory. When the sample is dynamically loaded, the diagnostic methods of full-ring XRD, PCI, and stereo-DIC are properly synchronized to record the deformation behavior at both continuum and microstructural scales as a function of the loading history. An advanced high-strength steel (AHSS) is used as a model material to demonstrate the capabilities of this new experimental method.

36 MATERIALS SCIENCE↗