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At least 1,027 records · Page 57
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Tribological Behavior of a Cr{sub 2}O{sub 3} Ceramic Coating/Steel Couple Under Dry Sliding and Heavy Loading Conditions

This work evaluates the effects of heavy loadings on a Cr{sub 2}O{sub 3} ceramic coating/steel couple under dry sliding and in conditions similar to those occurring in heavy-duty diesel engines. Two types of wear tests were performed by a standard pin-on-disc tribometer under high constant and variable loads. Before wear tests, microstructure and mechanical properties of coating and steel were determined by optical emission spectrometry, optical microscopy, roughness, microhardness and x-ray diffractometry (XRD). The friction coefficient was directly calculated by the tribometer. The wear rate of Cr{sub 2}O{sub 3} ceramic coating was evaluated by the wear volume and that of pins by weighing them before and after tests. The wear tracks on pins and coating surfaces were analyzed by XRD and by scanning electron microscopy with energy-dispersive spectroscopy. For all loads except the lowest constant one, the results indicated high friction and wear involving material removal from the coating surface, through a severe-oxidational wear associated with extensive cracking of the surface of the coating, softening of the carburizing steel and removal of the carburized layer of pins. The wear mechanism was mild-oxidational under the lowest constant load, which was therefore suggested as the limit for acceptable performance of the sliding couple under study.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Microstructure and Friction-Wear Behavior of Multi-arc Ion Plating TiAlNC Ceramic Coating on WC-6%Co Substrate

Nanocomposite coating could be used for machining tools, which can be used for cutting, drilling, milling, whetting, profiling, honing and superfinishing of various materials with high productivity. In this work, the TiAlNC ceramic coating was prepared by multi-arc ion plating method on WC-6%Co substrate. The microstructure and morphology of the coating were observed by scanning electron microscopy and transmission electron microscopy. The phase and chemical composition of the coating were determined by x-ray diffraction and x-ray energy-dispersive spectroscopy, respectively. The adhesive force of the coating was measured by a scratch tester, at the same time the friction-wear behavior of the coating was studied. The results show that there were TiN and (Ti,Al)(N,C) two phases, and there was the coexistence of amorphous and nanocrystalline in the coating. The chemical composition of the coating was composed of 20 ± 9 at.% Ti, 16 ± 5 at.% Al, 39 ± 5 at.% N and 25 ± 10 at.% C. The thickness of the coating was about 4.5 μm. The average root mean square value of the surface roughness was 225 ± 16 nm. A critical force for coating failure in scratch testing was about 25 N. The friction coefficients of the substrate and the coating were 0.55 and 0.35, respectively. The ceramic coating could improve the wear resistance of the substrate.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2019

Interaction Between Ceramic Molds and High-Speed Steel during Gravity and Vacuum Investment Casting

Ceramic molds containing the ZrSiO{sub 4}/SiO{sub 2} primary face coat with and without addition of cobalt aluminate were produced. After firing, the surface and the cross sections of the face coats were subjected to detailed characterization using XRD, SEM and EDS. The interaction between the mold systems and 0.9C-6W-5Mo-4Cr-2V high-speed steel was studied during the gravity and vacuum investment casting. During casting, the isostructural transformation of the initial ZrSiO{sub 4} filler occurred. For the mold without addition of the cobalt aluminate, two different types of interaction products [multicomponent phase containing O, Al, Zr, Fe, W and V and (Fe, W,Mo,Cr){sub 2}Al{sub 2}O{sub 6})] were revealed. An interaction layer of a depth in the range of 5-30 μm was thoroughly studied after casting into the mold containing the cobalt aluminate. Addition of the cobalt aluminate into the ceramic system provided significant refinement of the high-speed steel microstructure.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Interface-Driven Plasticity in Metal–Ceramic Nanolayered Composites: Direct Validation of Multiscale Deformation Modeling via In Situ Indentation in TEM

Here, we present in situ indentation in a transmission electron microscope on Al-TiN multilayers with individual layer thicknesses of 50 nm and 2.7 nm to explore the effect of length scales on the plastic co-deformability of a metal and a ceramic. At 50 nm, plasticity was confined to the Al layers with brittle fracture in the TiN layers. At 5 nm and below, cracking in TiN was suppressed with co-deformation evident in both layers. The in situ transmission electron microscopy (TEM) straining results demonstrate a profound size effect in enhancing plastic co-deformability in nanoscale metal-ceramic multilayers, as well as direct validation of ex situ and 3-D elastic–plastic deformation models.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Nano-scale microstructure damage by neutron irradiations in a novel Boron-11 enriched TiB 2 ultra-high temperature ceramic

Ultra-high temperature transition-metal ceramics are potential candidates for fusion reactor structural and plasma-facing components. We reveal the irradiation damage microstructural phenomena in Boron-11 enriched titanium diboride (TiB 2 ) using mixed-spectrum neutron irradiations, combined with state-of-art characterization using transmission electron microscopy (TEM) and high resolution TEM. Irradiations were performed using High Flux Isotope Reactor at ~220 and 620 °C up to 2.4 x 10 25 n.m -2 (E > 0.1 MeV). The calculated dose including contribution from residual Boron-10 ( 10 B) transmutation recoils, was ~4.2 displacements per atom. TiB 2 is susceptible to irradiation damage in terms of dislocation loop formation, cavities and anisotropic swelling induced micro-cracking. At both 220 and 620 °C, TEM revealed dislocation loops on basal and prism planes, with nearly two orders of magnitude higher number density of prism-plane loops. HRTEM, electron diffraction and relrod imaging revealed additional defects on {10$ \overline{1}\ $0} planes, identified as faulted prism-plane dislocation loops. High defect cluster density on prism planes will induce a-lattice parameter swelling of TiB 2 , as reported in literature. This anisotropic lattice parameter swelling induced grain boundary micro-cracking, the extent of which decreased with increasing irradiation temperature. The dominance of irradiation defect clusters on prism planes is different than typical hexagonal ceramics where dislocation loops predominantly form on basal planes, causing c-lattice parameter swelling. Helium generation and temperature rise from the transmutation of residual 10 B resulted in matrix and grain boundary cavities for the irradiation at 620 °C. In conclusion, the study additionally signifies isotopic enrichment as a viable approach to produce transition-metal diborides for potential nuclear structural applications.

36 MATERIALS SCIENCE↗
DOE OSTI2021

First principles study of the stability and thermal conductivity of novel Li-Be hybrid ceramics

Hybrid Li-Be ceramics, combining both tritium (T) breeder (Li) and neutron multiplier (Be) for use as part of the fuel cycle of future nuclear fusion reactors are proposed. The development of such hybrid materials may reduce thermal gradients through better matching of thermal properties, mitigating the detrimental effects that may accompany traditional breeder systems while maintaining acceptable neutron multiplication and T breeding. Here, first-principles methods are used to investigate stability and thermal transport properties of a set of compounds containing both Li and Be. It is demonstrated that BeLi 2 O 4 Ge and BeLi 2 O 4 Si are mechanically stable and have formation energies comparable with leading candidates for solid state breeder materials, Li 2 TiO 3 , Li 2 ZrO 3 . It is also demonstrated that similar to the leading candidates, these compounds are insulators with thermal transport defined by phonons. The calculated thermal conductivity of BeLi 2 O 4 Ge is slightly higher compared to Li 2 TiO 3 or Li 2 ZrO 3 while in the BeLi 2 O 4 Si it is almost three times higher compared to the rest of compounds due to a higher phonon group velocities and increased phonon lifetimes. These results indicate that hybrid Li-Be ceramics offer a potential route towards better matching of thermal properties with minimal functional property degradation, thereby offering better overall fuel cycle performance.

36 MATERIALS SCIENCE↗
DOE OSTI2023

In situ probing of interfacial roughness and transient phases during ceramic cold sintering process

The ceramic cold sintering process (CSP) offers an eco-friendly approach to producing fully dense ceramics at low temperatures. However, an incomplete mechanistic understanding hinders its optimization and widespread adoption. In this study, we analyze the microstructural and structural changes in ZnO, a model CSP system, using in situ synchrotron-based high-energy small-angle X-ray scattering and X-ray diffraction techniques. Our results reveal the time evolution of ZnO particles' surface area and roughness, reflecting the dissolution and re precipitation processes that enable densification. The in situ measurements supply valuable kinetic data for these stages of CSP. Alongside microstructural changes and densification, we observed the evolution of secondary phases representing reaction products between ZnO and acetic acid, the solvent used. The initial ZnO/solvent mixture's dominant secondary phase is attributed to zinc acetate, which is gradually replaced by a zinc soap-type structure during CSP. This structure has a large (≈ 21 Å) lattice parameter and is assumed to have a layered nature. The formation of this soap phase, which is retained in the sintered product as an intergranular component, appears to be a signature of successful cold sintering as it facilitates mass transport, leading to densification. Here, our study underscores the potential of in situ synchrotron characterization for revealing microstructural and phase-evolution details during CSP. These findings, which would be challenging to obtain through ex situ measurements, provide crucial data to guide and validate theoretical models, ultimately enhancing CSP's effectiveness and adoption.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of patterned inclusions on the fracture behavior of ceramic composites

Developments in additive manufacturing have enabled the reinforcement of ceramic composites across the scales. Understanding the fracture behavior of such composites is critical for structural design and engineering. However, systematic investigations on the relationship between the patterning characteristics and the effective fracture properties have been scarce. In this work, we propose a mixed-mode phase field model to investigate the effects of elastic modulus and pattern characteristics of circular inclusions on the fracture behavior of a ceramic composite beam. The modeling results have shown that the stiff and compliant inclusions can either repel or attract the crack. The extent of repelling and attraction can be controlled by altering the pattern characteristics. In addition, utilizing the relationship between the pattern characteristics and resulting fracture path, fracture growth can be controlled with appropriate inclusion properties. The targeted enhancement in fracture toughness can also be predicted using an effective fracture model linked with the underlying fracture path computed by the proposed mixed-mode phase field model.

36 MATERIALS SCIENCE↗
DOE OSTI2021

High performance protonic ceramic fuel cell systems for distributed power generation

The technology landscape around distributed generation continues to evolve in response to increasing demand for high-efficiency, low-emission, low-cost power generation. While emerging distributed power technologies, such as solid oxide fuel cells (SOFCs), continue to advance, they still face challenges due to their high capital costs, and shorter lifetimes that typically arise from electrochemical stack performance degradation at high operating temperatures (>750 °C). Recent advancements in protonic ceramic fuel cells (PCFCs) offer the potential to mitigate drawbacks of their higher temperature SOFC counterparts by enabling lower operating temperatures (550 °C–600 °C) with acceptable power densities. Here the present work leverages the recent progress in protonic ceramic cell and stack technology development to generate viable system configurations and evaluate the energetic performance potential of PCFC-based systems for stationary power generation. Process system engineering of two water-neutral system concepts, which provide 25 kW of electric power and process hot water, are presented and evaluated through sensitivity studies. Stack design parameters are altered and used to gauge the effect on system performance characteristics, including fuel cell stack and balance-of-plant sizing requirements, and electric and cogeneration efficiencies. The study finds that the potentially high per-pass fuel utilization capability of PCFC stacks could enable unprecedented electric efficiencies approaching 70% without hybridization with other prime movers.

25 ENERGY STORAGE↗
DOE OSTI2019

Thermal conductivity measurements and modeling of ceramic fiber insulation materials

Ceramic fiber insulation materials are used in numerous applications (e.g. aerospace, fire protection, and military) for their stability and performance in extreme environments. However, the thermal properties of these materials have not been thoroughly characterized for many of the conditions that they will be exposed to, such as high temperatures, pressures, and alternate gaseous atmospheres. The resulting uncertainty in the material properties can complicate the design of systems using these materials. In this study, the thermal conductivity of two ceramic fiber insulations, Fiberfrax T-30LR laminate and 970-H paper, was measured as a function of atmospheric temperature and compression in an air environment using the transient plane source technique. Furthermore, a model is introduced to account for changes in thermal conductivity with temperature, compression, and ambient gas. The model was tuned to the collected experimental data and results are compared. Lastly, the tuned model is also compared to published data sets taken in argon, helium, and hydrogen environments and agreement is discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2021

A mechanistic damage model for solid oxide fuel cell ceramic materials - Part I: Constitutive modeling

A multiscale mechanistic damage model for solid oxide fuel cell (SOFC) ceramics that combines micromechanics of stiffness reduction due to material porosity change and microcracking with a continuum damage mechanics (CDM) description for the evolution of microcracks up to fracture is developed in this work. The model also accounts for volumetric swelling of the anode due to redox cycling. Porosity change and swelling during redox combined with normal operating thermomechanical loads could increase the stress, strain and damage distributions in SOFC stacks leading them to failure. The proposed model involves three governing parameters: (i) the porosity in terms of the pore or void volume fraction, (ii) material swelling magnitude prescribed at a given loading step, and (iii) the damage variable that describes microcracking caused by thermomechanical loads and swelling. Pores and microcracks in the ceramics are modeled as randomly distributed ellipsoidal inclusions with negligible stiffness by an Eshelby-Mori-Tanaka formulation combined with an inclusion orientation distribution method. Microcracking damage evolution is described by a CDM formulation. Volumetric swelling is treated in a similar way to thermal expansion in the constitutive relations. After validation and numerical checks, the damage model is used to analyze a simplified SOFC positive-electrode/electrolyte/negative-electrode (PEN) structure subjected a redox cycle in addition to thermomechanical loads experienced during normal operation of a SOFC stack.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2022

Dimensionless parameters for ballistic performance evaluation of ceramic-faced bicomponent targets against sharp-nosed projectiles

Two dimensionless parameters are proposed to give first-order approximations for the ballistic performance of ceramic-faced bicomponent armor plates impacted by conical-nosed steel projectiles. The current work collates expansive experimental data from Wilkins and Mayseless covering a broad range of material and mechanical properties, target construction, and projectile dimensions, the data is collapsed using the Hugoniot elastic limit of the ceramic strike face as a strength metric. We find that within datasets where experimental conditions are kept constant, a singular cubic curve can be generated, but variations in experimental conditions for the ballistic limit test between datasets can result in differences in the predictive curve coefficients.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Novel refractory high-entropy metal-ceramic composites with superior mechanical properties

A new concept of refractory high-entropy metal-ceramic composites (HEMCC) has been proposed that combines the outstanding physical properties of both high-entropy alloy (HEA) and high-entropy ceramic (HEC). As the first HEMCC system, to the best of our knowledge, TiTaNbZr-(TiTaNbZr)C, has been developed by a powder metallurgy process. The HEA and HEC phases exhibit body-centered cubic (BCC) and rock-salt B1 crystal structures, respectively, and both phases have non-equimolar chemical compositions. Further, with the increase of the HEC phase in HEMCC, the hardness is enhanced while the density and fracture toughness are decreased. HEA50C sintered from 50vol% HEA and 50vol% HEC precursor powders shows a favorable combination of flexural strength (541±48MPa) and fracture toughness (6.93±0.27 MPa·m 1/2 ) at room temperature and a high compressive strength at 1300ºC (275MPa). The optimized mechanical performance of HEMCC might be attributed to the combination of the ductile HEA and strong HEC phases, smaller grain size, and crack arrest at HEC/HEA interfaces.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2019

Monitoring structural variation on Gd ratio of La modified bismuth ferrite ceramics with enhanced magnetization

Critical structural variation and dielectric properties were investigated in Lanthanum and Gadolinium co-substituted bismuth ferrite (Bi 0.9 La 0.1 Fe 1-x Gd x O 3 (x = 0.01, 0.03, 0.05, 0.07, 0.1, and 0.15). Conventional solid state reaction technique was used to synthesize ceramic samples. To investigate the influence of co-substitution on the phase formation and crystal structure, X-ray diffraction method (XRD), Scanning electron microscopy (SEM) and Raman spectroscopy were utilized. Probing the structural properties by changing Gd ratio was carried out to ensure single phase of rhombohedral R3c structure. Hence, the exploration of dielectric properties of single phase modified BiFeO 3 (BFO) ceramic was executed by room temperature capacitance and loss tangent measurements. It was found that by substitution of 10 mol% La for Bi and up to 5 mol% Gd for Bi, perovskite structure of rhombohedral symmetry and R3c space group were formed. This possessed enhanced magnetization and reduced dielectric loss compared to pure BFO.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Fracture toughness measurement of ceramics with fuel pellet geometry

The crack initiation of nuclear fuel pellets, driven by extreme temperature gradients, is a critical factor impacting reactor performance. Although this fact is widely acknowledged, there is limited fracture toughness data for specimens with representative geometry and fabricated using relevant processing methods. Here, to address this, a new chevron-notched short-rod specimen configuration with diameter and length both equal to 10 mm, representative of a conventional fuel pellet and tested in tension, was developed in an attempt to validly measure Mode I fracture toughness, K Ic . Test calibration was carried out by testing polycrystalline ZrO 2 , SiC, and Si 3 N 4 ceramics fabricated with conventional fuel pellet geometry and known fracture toughnesses. The results suggest that the method described in this paper produces valid K Ic measurements using conventional ceramic fuel pellets.

Ceramics↗
DOE OSTI2025

High-resolution characterization of ceramic-metal interface of TiN coating on ferritic-steels for nuclear application

Advanced fuel cladding is critical for fast reactors, offering sufficient thermal conductivity, mechanical and dimensional stability and radiation tolerance of the cladding base material. Additionally, it must provide corrosion resistance and high temperature coolant compatibility on the cladding outer surface, as well as chemical stability on the cladding inner wall against fuel cladding chemical interaction (FCCI). TiN ceramic coating has been considered an effective diffusion barrier for inner and outer cladding-walls for enhanced performance. The TiN-metal interface microstructure and chemistry play a critical role in coating bond strength and integrity under harsh conditions. High-resolution transmission electron microscopy characterization of ceramic-metal interface at atomic resolution in unirradiated, irradiated and thermal cycled conditions were performed. The interface remained intact after irradiation up to 200 dpa or thermal cycling five times up to 550 °C. In conclusion, this work discusses the potential impact of these results on coating performance and design for advanced claddings.

36 - MATERIALS SCIENCE↗
DOE OSTI2024

Unraveling the conundrum of electronic leakage in protonic ceramic cells: Operation-specific insights and rational design strategies

Electronic conduction through proton-conducting electrolytes significantly impairs the efficiency of protonic ceramic cells (PCCs). Here, in this study, we explore the electron and ion mixed transport properties of four common protonic ceramics, BaZr 0.8 Y 0.2 O 3-δ (BZY82), BaZr 0.7 Ce 0.2 Y 0.1 O 3-δ (BZCY721), BaZr 04 Ce 0.4 Y 0.1 Yb 0.1 O 3-δ (BZCYYb4411), and BaZr 0.1 Ce 0.7 Y 0.1 Yb 0.1 O 3-δ (BZCYYb1711). It marks the first instance of investigating these properties under operation-specific scenarios: fuel side of electrolysis cell, air side of electrolysis cell, fuel side of fuel cell, and air side of the fuel cell. BZCYYb1711 exhibits the highest ionic conductivity, but two to three times higher electronic leakage when exposed to oxygen-containing environments than the others. BZY82 exhibits approximately two times higher electronic leakage in a hydrogen-containing environment. BZCY721 demonstrates excellent ion transport numbers (~0.95) across these four operating conditions. BZCYYb4411 behaves quite similarly to BZCY721. The most challenging operating environment for all candidates is the air side of fuel cell mode. This mode leads to a high initial electronic leakage, followed by a significant increase with polarization. The probable cause for this behavior is a H 2 -free, polarization-induced reduction that leads to the formation of V$^•_O$. The electron small polaron associated with V$^•_O$ is released by the electrical field due to the Poole-Frenkel effect. ZnO and NiO sintering aids are found to be detrimental to the ionic conductivity of the electrolytes. In particular, NiO substantially lowers the ion transport number. The correlation of the operation-specific electronic leakage to full cells is discussed. It is suggested that a rational PCC design should synergistically couple BZCYYb1711 at fuel side with BZCY4411 at air side to deliver a well-balanced performance and faradaic efficiency simultaneously, and the high temperature sintering process with a NiO fuel electrode should be shortened or replaced by ultra-fast sintering techniques or using a fuel electrode scaffold-infiltration fabrication strategy.

42 ENGINEERING↗
DOE OSTI2015

Structural analysis of Fe–Mn–O nanoparticles in glass ceramics by small angle scattering

Magnetic nanocrystals containing Fe and Mn were obtained by annealing of silicate glasses with the composition 13.6Na{sub 2}O–62.9SiO{sub 2}–8.5MnO–15.0Fe{sub 2}O{sub 3−x} (mol%) at 580 °C for different periods of time. Here, we present Small Angle Neutron Scattering using Polarized neutrons (SANSPOL) and Anomalous Small Angle X-ray Scattering (ASAXS) investigation on these glass ceramic samples. Analysis of scattering data from both methods reveals the formation of spherical core–shell type of nanoparticles with mean sizes between 10 nm and 100 nm. ASAXS investigation shows the particles have higher concentration of iron atoms and the shell like region surrounding the particles is enriched in SiO{sub 2}. SANSPOL investigation shows the particles are found to be magnetic and are surrounded by a non-magnetic shell-like region. - Graphical abstract: Magnetic spherical core–shell nanoparticles in glass ceramics: SANSPOL and ASAXS investigations. - Highlights: • Formation and growth mechanisms of magnetic nanoparticles in silicate glass. • SANSPOL and ASAXS methods employed to evaluate quantitative information. • Analyses showed formation of nanoparticles with spherical core–shell structures. • Core of the particle is magnetic and surrounded by weak magnetic shell like region.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗