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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 919 records · Page 51
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

A New Method of Selective Laser Cladding

A new approach to selective laser cladding using conical laser beams has been elaborated. The initial round laser beam is divided into two or more circular beams with regulated distribution of the laser power between them. The circular beams are converted into conical beams that are focused separately on the surface and on different areas of the deposited material for their efficient heating. The delivery of laser energy into the powder stream is very effective because it provides a complete uniform absorption of laser energy in a dense powder stream (10{sup 4}–10{sup 6} cm{sup –3}). Under wire deposition, substrate heating reduces residual stresses due to temperature gradients and compensates for heat loss from the deposition zone by thermal conduction. The required power density for melt contact formation is significantly reduced.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2014

Effect of AC target power on AlN film quality

The influence of alternating current (AC) target power on film stress, roughness, and x-ray diffraction rocking curve full width half maximum (FWHM) was examined for AlN films deposited using S-gun magnetron sputtering on insulative substrates consisting of Si wafers with 575 nm thermal oxide. As the AC target power was increased from 5 to 8 kW, the deposition rate increased from 9.3 to 15.9 A/s, film stress decreased from 81 to −170 MPa, and the rocking curve FWHM increased from 0.98 to 1.03°. AlN film behavior is observed to change with target life; films deposited at 200 kWh target life were approximately 40 MPa more compressive and had 0.02° degree higher rocking curve FWHM values than films deposited at 130 kWh. AlN films deposited in two depositions were compared with films deposited in a single deposition, in order to better characterize the growth behavior and properties of AlN films deposited on an existing AlN film, which is not well understood. Two deposition films, when compared with single deposition films, showed no variation in residual stress trends or grain size behavior, but the average film roughness increased from 0.7 to 1.4 nm and rocking curve FWHM values increased by more than 0.25°.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Effects of substrate bias and tilt on magnetron sputtered boron carbide films

Maintaining high density and good mechanical properties at oblique angles for magnetron sputtered amorphous boron carbide films remains a challenge. In this study, we investigate the effect of the substrate bias on density, residual stress, mechanical properties, and morphology of boron carbide films deposited via direct current magnetron sputtering with a full-face erosion magnetron source in a mixed Ar-Ne plasma. Results show that films deposited at oblique substrate tilt angles on substrates biased at -50 V possess significantly lower oxygen content, superior mechanical properties, and higher density compared to their electrically grounded counterparts. In conclusion, these enhancements observed at oblique angles, while promising, come at the cost of larger residual compressive stress and higher Ne incorporation in films.

Materials science↗
DOE OSTI2019

High-Temperature Properties and Microstructural Stability of the AISI H13 Hot-Work Tool Steel Processed by Selective Laser Melting

The microstructural stabilities, softening resistance, and high-temperature tensile properties of the H13 hot-work tool steel by selective laser melting (SLM) were systematically studied. A series of tempering procedures were performed on the as-SLMed specimens. Afterwards, the mechanism of softening resistance behavior was discussed based on the XRD, SEM, EBSD observations, hardness measurements, and high-temperature tensile tests. It was found that the as-SLMed H13 consisted of α-iron and γ-iron. The carbide-stabilizing elements aggregated as the cell-like substructures for the rapid solidification of the SLM process. After the softening resistance treatment, the retained austenite transformed to ferrite and carbide mixtures. The cell-like substructures dissolved slowly into the matrix when the temperature was below 550 °C. These factors increased the hardness and retarded the softening of the material. When the temperature was 600 °C, the microstructural constituents transformed to soft ferrite and globular carbides, which lead to a considerable decrease of the hardness. Due to the grain refinement, solid solution strengthening, and residual stress, the as-SLMed H13 exhibited better mechanical properties than that of the wrought counterparts.

36 MATERIALS SCIENCE↗
DOE OSTI2024

A Comprehensive Review on Finite Element Analysis of Laser Shock Peening

Laser shock peening (LSP) is a formidable cold working surface treatment that provides high-energy precision to enhance the mechanical properties of materials. This paper delves into the intricacies of the LSP process, offering insights into its methodology and the simulation thereof through the finite element method. This review critically examines various points, such as laser energy, overlapping of shots, effect of LSP on residual stress, effect of LSP on grain refinement, and algorithms for simulation extrapolated from finite element analyses conducted by researchers, shedding light on the nuanced considerations integral to this technique. As the significance of LSP continues to grow, the collective findings underscore its potential as a transformative technology for fortifying materials against mechanical stress and improving their overall performance and longevity. The discourse encapsulates the evolving landscape of the LSP, emphasizing the pivotal role played by finite element analysis in advancing our understanding and application of this innovative surface treatment.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Different Forms of Application of a Laser Surface Treatment on Fatigue Crack Growth of an AA6013-T4 Aluminum Alloy

This work analyzes the effect of surface-localized laser heating treatment on the fatigue crack growth (FCG) rate on region II of the sigmoidal da/dN × ΔK curve of an aerospace-grade AA6013-T4 aluminum alloy sheet with 1.3 mm thickness. The influence on microstructure changes is also evaluated. Aiming to improve the FCG resistance without changing the mechanical behavior of the alloy, a Yb:fiber laser beam is defocused to generate a laser spot diameter of 2 mm, using 200 W power and a laser speed of 2 mm/s. Two laser lines are applied over fatigue C(T) specimens in two different forms: on only one and on both lateral specimen surfaces. Guinier–Preston zones, dispersoids and coarse constituent particles are found on the base material. On the heat-treated material, the same precipitates and also β′ and Q′ precipitates are found. These microstructural variations due to the laser thermal cycle, together with the presence of induced compressive residual stresses, improved the fatigue behavior of the material. The FCG retardation is optimized when two laser lines were applied on both lateral surfaces of the specimen.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Inelasticity and Nanostructured Dislocation Deformation of Aluminum–Silicon Alloy with a Supermodified Eutectic Structure

Young’s modulus and the logarithmic decrement of oscillations at a frequency of ~100 kHz as well as the subgrain size and residual stresses in the strontium modified alloy of aluminum with 15 wt % silicon have been studied. The alloy was obtained with a solidification rate of 1 mm/s at the shifted eutectic point. The dependence of inelastic dislocation deformation on the applied oscillating stress has been obtained and analyzed. The effect of strontium modification on the microstrain diagram can be accounted for by transformation of the lamellar fiber structure of eutectic silicon into a superfine fiber structure.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2014

Thickness effect on the structural and electrical properties of poly-SiGe films

Graphical abstract: - Highlights: • Stress and Young's modulus of poly-SiGe film are linked to the grain columnar structure. • The above properties remain unchanged for poly-SiGe films thicker than 40 nm. • The point of transition is close to the electron mean free path for SiGe. • Both the resistivity and Hall mobility follow a similar trend. - Abstract: As lateral dimensions of electromechanical devices are scaled down to length scales comparable to electron mean free paths, the influence of thickness effect on their properties becomes sine qua non. This paper presents a detailed study of thickness effect on the Young's modulus, residual stress, resistivity and Hall mobility of ultrathin poly-Si{sub 11}Ge{sub 89} films deposited by low pressure chemical vapour deposition. The Young's moduli for the films thicker than ∼40 nm are close to the bulk value (135 GPa) while those of the thinner films are much lower. The reduction in resistivity and subsequent improved Hall mobility as thickness increases are discussed in light of surface morphology which is evident from atomic microscopy images. The near constant values of Young's modulus, resistivity and Hall mobility for the films thicker than ∼40 nm are attributed to the columnar grain structure as confirmed by the transmission electron microscopy images.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Thermo-mechanical simulations of CO{sub 2} laser–fused silica interactions

CO{sub 2} laser heating of silica glass is used in many scientific and industrial applications. Particularly, localized CO{sub 2} laser heating of silica glass has demonstrated its ability to mitigate surface damage on optics used for high power laser applications. To develop such applications, the control of temperature, heat affected area, and resulting mechanical stresses are critical. Therefore, it is necessary to understand the silica transformation, the material ejection, and the thermo-mechanical stresses induced by the laser heating and subsequent cooling. In this paper, we detail the development of comprehensive thermo-mechanical numerical simulations of these physical processes, based on finite-element method. The approach is developed for 2D or 3D cases to tackle the case of a moving beam at the surface of the sample, and we particularly discuss the choice of the different parameters based on bibliographic inputs. The thermal and mechanical numerical results have been compared to different dedicated experimental studies: infrared thermography measurements at the surface of the irradiated area, optical profilometry measurements of the laser-processed sites, and photo-elastic measurements. Very consistent results are obtained between numerical and experimental results for the description of the temperature gradients, the material ejection, and the residual stresses.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
NASA NTRS2015

Multiscale Modeling of Ceramic Matrix Composites

Results of multiscale modeling simulations of the nonlinear response of SiC/SiC ceramic matrix composites are reported, wherein the microstructure of the ceramic matrix is captured. This micro scale architecture, which contains free Si material as well as the SiC ceramic, is responsible for residual stresses that play an important role in the subsequent thermo-mechanical behavior of the SiC/SiC composite. Using the novel Multiscale Generalized Method of Cells recursive micromechanics theory, the microstructure of the matrix, as well as the microstructure of the composite (fiber and matrix) can be captured.

ceramic matrix composites↗
DOE OSTI2019

Lead Whisker Formation in the Gold-Lead System

Metallic whiskers of pure lead (Pb) have been observed in the solder of several types of transistors. The conditions that lead to these whiskers were evaluated, including characterization of the whisker lengths and whisker density as a function of time and temperature. The potential cause and impact they would have on the reliability of electronics has been investigated. Based on these results, it is hypothesized that these whiskers may be caused by the relief of residual stresses that are created during the evolution of Au-In and/or Au-Pb intermetallic compounds or, possibly, by a decomposition of the AuPb{sub 3} phase. Due to their small size, the Pb whiskers that were observed were considered to not be a reliability concern, but similar or larger Pb whiskers could cause electrical failure in some applications.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Microstructure and mechanical properties of Ti–B–C–N–Si nanocomposite films deposited by unbalanced magnetron sputtering

Quinary Ti–B–C–N–Si nanocomposite thin films were deposited on AISI 304 stainless steel substrates by d.c. unbalanced magnetron sputtering from a TiB{sub 2}–TiC compound target and a pure Si target. The relationship between microstructure and mechanical properties of the films was investigated in terms of the nanosized crystallites/amorphous system. The synthesized Ti–B–C–N–Si films were characterized using x-ray diffraction, x-ray photoelectron spectroscopy, atomic force microscopy, and high resolution transmission electron microscopy. The results showed that the Ti–B–C–N–Si films were nanocomposites composed of nanosized TiB{sub 2}, TiC, and TiSi{sub 2} crystallites (2-3 nm in size) embedded in an amorphous matrix. The addition of Si to the Ti–B–C–N film led to precipitation of nanosized crystalline TiSi{sub 2} and percolation of amorphous SiC phases. The Ti–B–C–N–Si films with up to 7 at. % Si content presented high hardness (≥35 GPa), H/E (≥0.0095), and W{sub e} (>50%) with compressive residual stress (∼0.5 GPa). A systematic investigation on the microstructure and mechanical properties of Ti–B–C–N–Si films containing different Si contents is reported.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Toward Process-Based Quality through a Fundamental Understanding of Weld Microstructural Evolution

Here, in this overview paper, the possibility of qualifying welded components by integrating software and hardware tools that are capable of describing physical processes that occur during welding is explored. The existing and emerging tools to define geometrical boundary conditions, process parameters, heat and mass transfer, solidification, solid-state transformation, plastic deformation, distortion, residual stress, and performance of welded components are reviewed. Existing challenges relevant to the fundamental understanding of complex alloying, processing environment, and transients in energy deposition are discussed with reference to microstructure evolution. Finally, approaches to address these challenges were articulated with published case studies relevant to welding and additive manufacturing.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Characteristics of Bi-metallic Interfaces Formed During Direct Energy Deposition Additive Manufacturing Processing

Various additive manufacturing processes are being evaluated to reduce the time and cost for fabrication of low volume, complex, and multifunctional assemblies. This study evaluated two direct energy deposition processes for the fabrication of large bi-metallic structures. The materials evaluated were Inconel 625 and copper alloy C18150, which are used in various high heat flux applications. Inconel was deposited onto the C18150 substrate using blown powder and wire-fed processes. Complete bonding was obtained in both processes and the resulting interfaces were evaluated using microscopy and indentation testing. Differences were observed in the interface region suggesting the kinetic energy of the blown powder process resulted in more residual stress at the interface, promoting recrystallization and enhanced diffusion. This created a broader interface in the blown powder specimens compared to a narrower mechanically mixed interface with the wire-fed process.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Improvement of Al/Steel Tungsten Inert Gas Welding–Brazing Joint by High-Energy Shot Peening

High-energy shot peening treatment was applied to improve the Al/steel tungsten inert gas welding–brazing lap joint. The mechanical properties and microstructure evolution of the joint were investigated. Results showed that the mechanical properties of weld were evidently reinforced due to microstructure transformation of joint surface layer. The grain structure in the joint surface layer was distorted and refined. Large compressive residual stress was introduced into the joint surface, and its hardness obviously increased due to strain hardening. When the peening pressure was 0.15 MPa, the tensile shear strength of the joint reached the maximum value (199.6 MPa), which was 16.5% higher than that of the as-welded joint.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Characterization of Thick Tungsten Coating on Cu Alloy Substrate Prepared by Electrodeposition

The W coating with the thickness over 1 mm was obtained by pulse electrodeposition on large CuCrZr alloy in a Na{sub 2}WO{sub 4}–WO{sub 3} molten salt. The composition of this system keeps unchanged with the duration of electrodeposition. The coating’s structure, morphology and contents were investigated by XRD, XPS and SEM. The electrodepostion tungsten coating was compact and without void. The residual stress in surface of W coating was calculated to be a compressive stress with the value of 225 MPa. The W coating comprised an inner tooth-like layer and an outer columnar layer. The bonding strength between W coating and CuCrZr susbtrate was near 60 MPa; the thermal conductivity parallel to the crystal growth direction was measured to be 150.86 W m{sup −1} K{sup −1}.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Influence of the Microstructure on Magnetic Stray Fields of Low-Carbon Steel Welds

This study examines the relationship between the magnetic mesostructure with the microstructure of low carbon steel tungsten inert gas welds. Optical microscopy revealed variation in the microstructure of the parent material, in the heat affected and fusion zones, correlating with distinctive changes in the local magnetic stray fields measured with high spatial resolution giant magneto resistance sensors. In the vicinity of the heat affected zone high residual stresses were found using neutron diffraction. Notably, the gradients of von Mises stress and triaxial magnetic stray field modulus follow the same tendency transverse to the weld. In contrast, micro-X-ray fluorescence characterization indicated that local changes in element composition had no independent effect on magnetic stray fields.

42 ENGINEERING↗
DOE OSTI2014

Power optics

By using the theory we developed in the early 1970s, a broad range of phenomena is considered for an optical surface of a solid body that is exposed to radiation arbitrarily varying in time and producing temperature fields, thermoelastic stresses and thermal deformations on the surface layer. The examination is based on the relations (which are similar to Duhamel's integral formula from the theory of heat conduction) between the quantities characterising the thermal stress state in any nonstationary regimes of energy input into a solid. A peculiar feature of the analysis of the thermal stress state in this case consists in the fact that this relation comprises time as a parameter, which in turn is a consequence of incoherence of the quasi-stationary problem of thermoelasticity. This phenomenon is particularly important for the optics of high-power, high-pulse repetition rate lasers, which are being actively developed. In the review, we have recently published in Laser Physics, the thermal stress state of a solid is analysed. In this state, time is treated as an independent variable used in differentiation. Such an approach greatly reduces the applicability of the method. The review published contains data on the use of capillary porous structures made of various materials with different degrees of the surface development. Moreover, such structures can be efficiently employed to increase the heat exchange at a temperature below the boiling point of the coolant. In the present review we discuss the dependences of the limiting laser intensities on the duration of a pulse or a pulse train, corresponding to the three stages of the state of the reflecting surface and leading to unacceptable elastic deformations of the surface, to the plastic yield of the material accompanied by the formation of residual stresses and to the melting of the surface layer. We also analyse the problem of heat exchange in the surface layer with a liquid metal coolant pumped through it. The theoretical estimates are compared with the experimental data. We discuss the issues related to the technology of fabrication of power optics elements based on materials with a porous structure, of lightweight highly stable large optics based on highly porous materials, multi-layer honeycomb structures and silicon carbide, as well as problems of application of physical and technical fundamentals of power optics in modern cutting-edge technology. (invited paper)

36 MATERIALS SCIENCE↗