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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 955 records · Page 53
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Sandia Fracture Challenge 3: detailing the Sandia Team Q failure prediction strategy

The third Sandia Fracture Challenge illustrated the geometric and material uncertainties presented by modern additive manufacturing techniques. Tasked with the challenge of predicting failure of a complex additively-manufactured geometry made of 316L stainless steel, we combined a rigorous material calibration scheme with a number of statistical assessments of problem uncertainties. Particularly, we used optimization techniques to calibrate a rate-dependent and anisotropic Hill plasticity model to represent material deformation coupled with a damage model driven by void growth and nucleation. Through targeted simulation studies we assessed the influence of internal voids and surface flaws on the specimens of interest in the challenge which guided our material modeling choices. Employing the Kolmogorov–Smirnov test statistic, we developed a representative suite of simulations to account for the geometric variability of test specimens and the variability introduced by material parameter uncertainty. This method allowed the team to successfully predict the failure mode of the experimental test population as well as the global response with a high degree of accuracy.

316L stainless steel↗
DOE OSTI2017

Thermal Evolution of the Proton Irradiated Structure in Tungsten–5 wt% Tantalum

We have monitored the thermal evolution of the proton irradiated structure of W–5 wt% Ta alloy by in-situ annealing in a transmission electron microscope at fusion reactor temperatures of 500–1300 °C. The interstitial-type a/2<111> dislocation loops emit self-interstitial atoms and glide to the free sample surface during the early stages of annealing. The resultant vacancy excess in the matrix originates vacancy-type a/2<111> dislocation loops that grow by loop and vacancy absorption in the temperature range of 600–900 °C. Voids form at 1000 °C, by either vacancy absorption or loop collapse, and grow progressively up to 1300 °C. Tantalum delays void formation by a vacancy-solute trapping mechanism.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Fabrication and Properties of a Novel Porous Material from Biopolymer and Natural Rubber for Organic Compound Absorption

Maleate poly (vinyl alcohol) (PVAM)-graft water soluble polymer with deproteinized natural rubber (DPNR) porous materials were prepared using the freeze drying technique. The effect of the water soluble polymer type (chitosan (CS) and gelatin (GT)) and the DPNR content was studied. The mechanical properties of the porous materials were improved by the addition of the DPNR. The results showed that the addition of the DPNR improved the water resistance of the porous material. Many micro-voids were formed after the PVAM was grafted with the water soluble polymers as observed under SEM, leading to changes in porosity and density. The highest number of micro-voids was found in the PVAM-graft-chitosan (sPVAM-g-CS) sample while the minimum number of microvoids was found in the maleate poly (vinyl alcohol) (sPVAM). The swelling ratio of the nPVAM significantly improved after the freeze drying process. The PVAM-graft-gelatin (sPVAM-g-GT) gave the maximum swelling ratio in water. After the DPNR was added to the sPVAM-g-GT, the pore size of the porous material significantly decreased and the size distribution became narrower. The moisture absorption, moisture content and swelling ratio of the porous material decreased after blending with the DPNR but the tear strength and rebound resilience of the porous material was enhanced. The macroporous material was able to be reused the maximum number of over 30 times as organic compound-absorbent material and it easily decomposed in nature.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Formation of High-Field Pinning Centers in Superconducting MgB{sub 2} Wires by Using High Hot Isostatic Pressure Process

This paper demonstrates the effects of hot isostatic pressure (HIP) on the structure and transport critical parameters of in situ MgB{sub 2} wires without a barrier. Our results show that only HIP and nano-boron allow the formation of more high-field pinning centers, which lead to the increase in critical current density (J{sub c}) at high applied magnetic fields. Nano-boron and annealing at a low pressure increase the J{sub c} in the low magnetic field. This indicates that nano-particles create more high-field pinning centers. In addition, the results show that nano-boron improves the connection between the grains. Scanning electron microscope results show that HIP increases the reaction rate between Mg and B, density, and homogeneity of the MgB{sub 2} material. Additionally, HIP allows to create a structure with small grains and voids and eliminates the significance of the number of voids. High isostatic pressure allows to obtain high J{sub c} of 10 A/mm{sup 2} (at 4.2 K) in 10 T and increases irreversible magnetic field (B{sub irr}) and upper critical field (B{sub c2}). Measurements show that these wires have high critical temperature of 37 K.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2023

Effect of tension during sulfonation stabilization for UHMWPE-derived carbon fibers

Polyethylene is a promising low-cost alternative precursor material for carbon fiber production, but it has yet to show mechanical properties near or surpassing polyacrylonitrile-derived carbon fibers. The high molecular weight and order of ultra-high molecular weight polyethylene (UHMWPE) may offer a pathway to realizing this promise by enabling long-range graphitic structure formation and superior mechanical properties. The tension applied during the precursor stabilization process is crucial to maintaining the shape of the fibers during the conversion process, but no published study has yet probed the relationship between sulfonation tension and carbon fiber microstructure and mechanical properties. In this work, a logarithmic sweep of tensile stress was applied to UHMWPE fibers during the stabilization process followed by carbonization. Increasing tension significantly reduced fiber shrinkage, resulted in straighter fibers with less severe kink bands, and greatly improved the mechanical properties of the fibers. Raman spectroscopy and X-ray diffraction revealed that in all cases the carbon fibers were largely amorphous, but increasing tension resulted in increased size and alignment of the turbostratic crystallites with the fiber axis. Large voids were present in the sample fibers, so the Griffith-Irwin relation was employed to predict the potential ultimate tensile strength of the fibers with voids reduced to sizes comparable to commercially produced fibers. Furthermore, this work demonstrates the importance of tension applied during the stabilization of polyethylene fibers for carbon fiber production and establishes a framework for achieving high mechanical properties from these precursors.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Impact of Gold Thickness on Interfacial Evolution and Subsequent Embrittlement of Tin–Lead Solder Joints

Although gold remains a preferred surface finish for components used in high-reliability electronics, rapid developments in this area have left a gap in the fundamental understanding of solder joint gold (Au) embrittlement. Furthermore, as electronic designs scale down in size, the effect of Au content is not well understood on increasingly smaller solder interconnections. As a result, previous findings may have limited applicability. The current study focused on addressing these gaps by investigating the interfacial microstructure that evolves in 63Sn-37Pb solder joints as a function of Au layer thickness. Those findings were correlated to the mechanical performance of the solder joints. Increasing the initial Au concentration decreased the mechanical strength of a joint, but only to a limited degree. Kirkendall voids were the primary contributor to low-strength joints, while brittle fracture within the intermetallic compounds (IMC) layers is less of a factor. The Au embrittlement mechanism appears to be self-limiting, but only once mechanical integrity is degraded. Sufficient void evolution prevents continued diffusion from the remaining Au.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Primary Processing Parameters, Porosity Production, and Fatigue Prediction for Additively Manufactured Alloy 718

Powder bed fusion processes commonly introduce voids and defects into components. It has been shown that many of these features and their size and shape characteristics are controllable through process parameter manipulation, but this process is typically time-consuming and expensive. In spite of this, an experiment was developed to explore a wide region of laser powder bed fusion process space, and several void measurements were obtained to characterize component density percentage, pore size, and pore shape. Then, multiple models commonly used in the literature to predict porosity were examined and compared with the experimental data. Using the developed porosity model, a fatigue life prediction framework was adapted, and the predictions were compared to the previously published experimental data. Results of this investigation reveal the strengths and weaknesses of multiple literature models in predicting porosity, and they depict how porosity and resulting fatigue lives vary across process space.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Radiation Enhanced Absorption of Frank Loops by Nanovoids in Cu

Neutron and heavy ion irradiation generally induces voids in metallic materials, and continuous radiations typically result in void swelling and mechanical failure of the irradiated materials. Recent experiments showed that nanovoids in nanotwinned copper could act as sinks for radiation-induced Frank loops, significantly mitigating radiation damage [Y. Chen et al., Nat. Commun. 6:7036 (2015)]. In this paper, we report on structural evolution of Frank loops under cascades and address the role of nanovoids in absorbing Frank loops in detail by using molecular dynamics simulations. Results show that a stand-alone Frank loop is stable under cascades. When Frank loops are adjacent to nanovoids, the diffusion of a group of atoms from the loop into nanovoids is accomplished via the formation and propagation of dislocation loops. The loop-nanovoid interactions result in the shrinkage of the nanovoids and the Frank loops.

36 MATERIALS SCIENCE↗
DOE OSTI2019

In-Situ Grain Resolved Stress Characterization During Damage Initiation in Cu-10%W Alloy

The evolution of stress during damage initiation and accumulation in a two-phase alloy consisting of a ductile copper (Cu) matrix with a randomly dispersed brittle tungsten (W) phase was studied using multiple non-destructive experimental probes. Neutron diffraction measurements were performed to examine the macroscopic strain partitioning between the two phases during a uniaxial tension test. The same material was then examined with high-energy x-ray diffraction microscopy (HEDM) and micro-computed tomography (μ-CT) measurements to monitor micromechanical field evolution. The neutron diffraction data indicated a redistribution of load between the Cu and W phases as deformation proceeds. Therefore, using HEDM to monitor individual grain micromechanical behavior, an increase followed by decrease in hydrostatic stress and a similar stress triaxiality behavior were found to occur in a subset of W grains. These same W grains were found to be in close proximity to voids observed via tomography at later stages of deformation. From these observations, we conclude that high stress triaxiality development in the W particles leads to decohesion of the interface between the Cu and W phases. The debonded regions eventually grew and coalesced with neighboring voids leading to material failure.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Porosity detection in electron beam-melted Ti-6Al-4V using high-resolution neutron imaging and grating-based interferometry

A high-resolution neutron tomography system and a grating-based interferometer are used to explore electron beam-melted titanium test objects. The high-resolution neutron tomography system (attenuation-based imaging) has a pixel size of 6.4 µm, appropriate for detecting voids near 25 µm over a (1.5 cm) 3 volume. The neutron interferometer provides dark-field (small-angle scattering) images with a pixel size of 30 µm. Moreover, the interferometer can be tuned to a scattering length, in this case, 1.97 µm, with a field-of-view of (6 cm)3. The combination of high-resolution imaging with grating-based interferometry provides a way for nondestructive testing of defective titanium samples. A chimney-like pore structure was discovered in the attenuation and dark-field images along one face of an electron beam-melted (EBM) Ti-6Al-4V cube. Tomographic reconstructions of the titanium samples are utilized as a source for a binary volume and for skeletonization of the pores. As a result, the dark-field volume shows features with dimensions near and smaller than the interferometer auto-correlation scattering length.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Strengthening of tungsten by coherent rhenium precipitates formed during low fluence irradiation

Experimental data show that the accumulation of rhenium and osmium from transmutation reactions severely affect the microstructural evolution and property degradation of tungsten-based materials under neutron irradiation. Theory and modeling have confirmed that Re atom transport in W is by irradiation-produced migrating self-interstitial atoms. With this diffusion mode in operation, a specific microstructure evolution is realized when at relatively low neutron fluence the Re-rich precipitates are formed, while the void and interstitial loop population development is suppressed, affecting the mechanical properties. Here, this research shows the effect of small coherent Re-rich precipitates on the dislocation glide under stress, investigated using the molecular dynamics approach with empirical interatomic potentials. The results are compared with an earlier simulation of void hardening in W. It is demonstrated that small coherent Re-rich precipitates of less than 6 nm diameter represent relatively weak obstacles for moving edge dislocations. The implication of these results on the interpretation of experimental results is discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Crystal chemistry at high pressure

The chemistry we are taught in school, and we experience in our daily existence occurs at 1 atm. However, pressure spans an astounding 62 orders of magnitude in the Universe in going from the void of interstellar space to the crushing conditions at the center of a neutron star. The way in which pressure affects chemistry is important for Earth and planetary sciences, materials science, in understanding the extreme conditions experienced in nuclear explosions, and it may be key in addressing the future energy needs of our society. In this article we outline how the often neglected pressure variable affects chemistry, beginning from the way in which atomic energy levels are altered. This lays the foundation for understanding the unique crystal and electronic structures that emerge when matter is squeezed, as well as pressure’s effect on chemical reactivity. Finally, we give an overview of the main concepts behind conventional, or phonon-mediated, superconductivity, and describe how the pressure variable may be key in discovering and designing light-element based materials whose superconducting critical temperatures approach room temperature. Here, we discuss some of the main families of superconducting hydrides that have been predicted computationally, and the experimental successes in this exciting and rapidly developing field.

Chemical bonding↗
DOE OSTI2014

Oxygen and relative humidity monitoring with films tailored for enhanced photoluminescence

In this study, approaches to generate porous or doped sensing films, which significantly enhance the photoluminescence (PL) of oxygen optical sensors, and thus improve the signal-to-noise (S/N) ratio, are presented. Tailored films, which enable monitoring the relative humidity (RH) as well, are also presented. Effective porous structures, in which the O 2 -sensitive dye Pt octaethylporphyrin (PtOEP) or the Pd analog PdOEP was embedded, were realized by first generating blend films of polyethylene glycol (PEG) with polystyrene (PS) or with ethyl cellulose (EC), and then immersing the dried films in water to remove the water-soluble PEG. This approach creates pores (voids) in the sensing films. The dielectric contrast between the films’ constituents and the voids increases photon scattering, which in turn increases the optical path of the excitation light within the film, and hence light absorption by the dye, and its PL. Optimized sensing films with a PEG:PS ratio of 1:4 (PEG’s molecular weight M w ~8000) led to ~4.4× enhancement in the PL (in comparison to PS films). Lower M w ~200 PEG with a PEG:EC ratio of 1:1 led to a PL enhancement of ~4.7×. Film-dependent PL enhancements were observed at all oxygen concentrations. The strong PL enhancement enables (i) using lower dye (luminophore) concentrations, (ii) reducing power consumption and enhancing the sensor’s operational lifetime when using organic light emitting diodes (OLEDs) as excitation sources, (iii) improving performance when using compact photodetectors with no internal gain, and (iv) reliably extending the dynamic range.

47 OTHER INSTRUMENTATION↗
DOE OSTI2016

Rationalization of anisotropic mechanical properties of Al-6061 fabricated using ultrasonic additive manufacturing

Ultrasonic additive manufacturing (UAM) is a solid-state process, which uses ultrasonic vibrations at 20 kHz along with mechanized tape layering and intermittent milling operation, to build fully functional three-dimensional parts. In the literature, UAM builds made with low power (1.5 kW) exhibited poor tensile properties in Z-direction, i.e., normal to the interfaces. This reduction in properties is often attributed to the lack of bonding at faying interfaces. The generality of this conclusion is evaluated further in 6061 aluminum alloy builds made with very high power UAM (9 kW). Tensile deformation behavior along X and Z directions were evaluated with small-scale in-situ mechanical testing equipped with high-resolution digital image correlation, as well as, multi-scale characterization of builds. Interestingly, even with complete metallurgical bonding across the interfaces without any discernable voids, poor Z-direction properties were observed. This reduction is correlated to coalescence of pre-existing shear bands at interfaces into micro voids, leading to strain localization and spontaneous failure on tensile loading.

Digital Image correlation↗
DOE OSTI2018

Effect of alloying elements on defect evolution in Ni-20X binary alloys

The effect of alloying elements on radiation-induced microstructural evolution in Ni and Ni-20X (X = Fe, Cr, Mn and Pd) binary alloys was investigated using ion irradiation and cross-sectional transmission electron microscopy. The three-dimensional migration mode is identified to be the dominating migration mechanism for interstitial clusters in these binary alloys, contrary to the one-dimensional mode that dominates in the well-studied dilute alloys. The results reveal that: (1) the average size of defect clusters decreases as the solute atomic volume size factor increases. Smaller void size in Ni-20Cr is attributed to faster vacancy mobility in the near surface region, and weaker vacancy binding energy beyond the irradiation peak than Ni-20Fe. The smaller voids observed in Ni-20Mn and Ni-20Pd beyond the damage peak are due to the stronger Mn/Pd-vacancy binding effect of largely oversized solute atoms. (2) Oversized solutes can act as strong trapping sites for interstitials. The larger the solute atomic volume factor, the stronger the trapping force. This leads to a more significantly sluggish interstitial migration and smaller dislocation loop size. The average dislocation loop size in Ni-20Fe was four times larger than Ni-20Pd (atomic volume factor being 10.6% and 41.3%) but an order of magnitude lower in density. The smaller dislocation loop size in Ni-20Cr is attributed to stronger interstitial binding of Cr-Ni. In conclusion, overall, the alloying effect on defects is more significant in concentrated binary alloys than in dilute binary alloys, due to the concentration difference of alloying atoms and the interstitial dominant migration mechanisms in the main irradiated region.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Transmutation-induced precipitation in tungsten irradiated with a mixed energy neutron spectrum

Transmutation-induced precipitation in neutron-irradiated tungsten is an important performance concern for its application as plasma facing material in fusion reactors. In this study, segregation and precipitation of transmutant elements in single crystal and polycrystal tungsten irradiated at 460–1100 °C to 0.02–2.4 displacements per atom (dpa) in the High Flux Isotope Reactor were investigated using transmission electron microscopy. The results indicated that nanoscale W-Re-Os clusters were identified in the low dose regime from 0.02 to 0.44 dpa with irradiation temperature lower than 800 °C while acicular-shape precipitates formed when irradiation dose is higher than 1.5 dpa. A tentative roadmap of the kinetics process of the transmutation-induced precipitation in neutron-irradiated tungsten is presented characterizing the defect features (i.e., W-Re-Os clusters and precipitates) consisting of transmutant elements in tungsten irradiated to various doses. All TEM-visible voids were associated with the acicular-shape precipitates. Voids were formed prior to the formation of acicular-shape precipitates and act as strong trapping sites for mobile species involved in the precipitation together with dislocations. Thermal stability of W-Re-Os clusters was assessed by performing a 2-h anneal at 1200 °C on tungsten irradiated to 0.44 dpa at 705 °C. In conclusion, the kinetics process of transmutant elements and radiation defects are discussed to reveal the underlying mechanisms controlling the formation of precipitates in tungsten.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Deformation mechanisms and ductile fracture characteristics of a friction stir processed transformative high entropy alloy

Deformation mechanisms of a friction stir processed Fe 40 Mn 20 Co 20 Cr 15 Si 5 transformative high entropy alloy using three different process parameters were studied to explain the microstructural dependence of tensile response in these specimens. The relative strain hardening contribution due to transformation and twinning effects was different for the three different microstructural conditions and thus resulted in different magnitude of work hardening. Crystal plasticity simulations confirmed that synergistic activity of face centered cubic and hexagonal close packed slip and twin mechanisms resulted in sustained work hardening and enhanced uniform elongation. The non-uniform ductility and extent of void nucleation and growth in these specimens were limited. Nevertheless, fractography and X-ray microscopy of fractured tensile specimens verified that microstructural flexibility induced different propensities for void growth and ductile fracture mode. Thus, alloy design induced phase stability, adaptive phase evolution due to friction stir processing, extent and kinetics of martensitic transformation and related work hardening capability of the individual phases combined together to determine the overall tensile response. The crystallographic orientation dependence of deformation induced phase transformation was also thoroughly studied. Finally, this study included quantitative determination of the crystallographic orientation where resolved shear stress on leading and trailing partial dislocations favored separation of the partials to cause transformation at a critical value of applied stress.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Electrochemical grand potential-based phase-field simulation of electric field-assisted sintering

Here, an electrochemical grand potential functional was proposed to describe the sintering of an ionic ceramic green body. The resultant phase-field description enables simulation of the consolidation of an arbitrary number of granular particles and their interactions with the surrounding void phase. The model includes the effects of charged vacancies and the associated interactions between internal and applied electric fields. Defect segregation to grain boundaries is also accounted for, as well as enhanced interfacial defect mobilities. The model was parameterized for Y 2 O 3 . Simulations of two-particle systems showed that the applied electric field had an increasingly important impact on neck growth as particle size increased. A sudden rapid increase in temperature occurred for larger field strengths, which has been reported to be correlated to the onset of a flash event in flash sintering. Simulations of many particles showed that internal heat generation by Joule heating was localized at particle–particle contacts (grain boundaries), even though their conductivities were lower than nearby internal particle-void interfaces. A percolative path for ionic charge across the green body and the ceramic sintered solid was thus defined, accelerating the Joule heating process as the porosity of the green body is removed.

36 MATERIALS SCIENCE↗