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At least 1,063 records · Page 59
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Ultrahigh strength and plasticity in laser rapid solidified Al–Si nanoscale eutectics

As-cast Al–20wt.% Si alloys were processed via laser rapid solidification (LRS) techniques to create eutectic microstructures with nanoscale interconnected, nanotwinned Si fibers. LRS morphologies exhibit higher flow stress, exceeding 800 MPa and uniform plastic deformation above 20% compared to as-cast alloy that fractures at strains below 8% at flow strength of approximately 200 MPa. The strengthening mechanisms of LRS morphologies are interpreted in terms of the interfacial constraints: increase in yield strength as well as strain hardening rate due to nanoscale confined slip in fibrous Al–Si eutectic, and load transfer and eventual plasticity in the nanoscale Si fibers.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Beyond the eutectic paradigm: nanolamellar patterns in a rapidly solidified peritectic alloy

Peritectic transformations are central to many structural alloys, yet pattern formation remains poorly understood due to complex growth dynamics and limited three-dimensional data. Here, we report an unusual two-phase microstructure in a Zn–Ag peritectic alloy subjected to rapid solidification by laser surface remelting. Synchrotron X-ray nanotomography reveals a lamellar structure of primary 𝜀-AgZn 3 and peritectic Zn with ∼700 nm spacing. Although resembling a eutectic morphology, this pattern forms without a eutectic reaction through non-steady coupled growth from the liquid. SEM and TEM-EDS confirm interface shapes and phase compositions. These findings expand the design space of peritectics for refined microstructural control.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Modeling mechanical behavior of an additively manufactured metal structure with local texture variations: a study on model form error

Here, the repetitive rapid solidification that occurs in metal additive manufacturing (AM) processes creates microstructures distinctly different from wrought materials. Local variability in AM microstructures (either by design or unintentional) raises questions as to how AM structures should be modeled at the part-scale to minimize modeling error. The key goal of this work is to demonstrate a posteriori error estimation applied to an AM part. It is assumed that the actual microstructure is unknown and an approximate, spatially uniform material model is used. Error bounds are calculated for many reference models based on AM microstructures with elongated grain morphology and localized or global fiber textures during a post-processing step. The current findings promote confidence that a posteriori model form error estimation could be used effectively in mechanical performance simulations of AM parts to quickly obtain quantitative error metrics between an approximate model result and many microstructure-based reference models. The a posteriori error estimation introduces significant time savings compared to computing the full reference model solutions. Tight bounds on model form error are obtained when texture variations in the reference models occur on large length scales. For materials with property variation at small length scales, multi-scale error estimation techniques are needed to properly account for the many interfaces present between areas with different properties.

36 MATERIALS SCIENCE↗
DOE OSTI2020

An implementation of the phase-field model based on coupled thermomechanical finite element solvers for large-strain twinning, explicit dynamic fracture and the classical Stefan problem

The implementation of a phase-field model in finite elements usually requires significant expertise and involves the development of a user element with additional degrees of freedom. An alternative implementation of the phase-field model within a thermo-mechanical finite element simulation package was presented in (Cho et al 2012 Int. J. Solids Struct. 49 1973–1992), where the phase-field variable is treated as the temperature degree of freedom. However, this approach has only been used for small strain phase-field modelling of martensitic transformations and quasistatic phase-field modelling of fracture. Here, we present a phase-field finite element implementation via the temperature degree of freedom for several additional cases from the literature: (i) the large-strain phase-field description of deformation twinning presented in (Clayton and Knap 2011 Physica D 240 841–858), (ii) phase-field description of brittle fracture with inertial effects based on the theory from (Molnár and Gravouil 2017, Finite Elem. Anal. Des. 130 27–38) and (Miehe et al 2010 Int. J. Numer. Methods Eng. 83 1273–1311) and (iii) the classical Stefan problem of solidification presented in (Mackenzie and Robertson 2002 J. Comput. Phys. 181 526–544). The last problem involves the temperature and phase-field variables as unknowns.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Effects of cyclic plasma heating on surface damage of micro-porous tungsten

The operating temperature window of solid tungsten (W) is dictated by its Ductile to Brittle Transition Temperature (DBTT) and re-crystallization temperature; roughly between 300-1300 °C. The brittleness of W at lower temperatures is exasperated when it undergoes recrystallization. We investigate here the thermal shock resistance of micro-porous W as a meta-material fabricated in a 3D open-cell network structure. We present experimental results for the effects of cyclic high-enthalpy arc-jet plasma on surface damage in three testing categories. Observed damage includes surface ablation of asperities, melting and solidification of W-fuzz on samples that have been exposed to a prior helium plasma, and micro-cracks at ligament triple junctions. Scanning electron microscope (SEM) observations show more micro-cracking on 54% and 23% foams compared to the 43% ones. In all tested samples, thermal expansion/contraction displacements were accommodated by ligament rotation and a network of micro-cracks. Furthermore, no large through-thickness crack were observed.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Laser metal deposition of refractory high-entropy alloys for high-throughput synthesis and structure-property characterization

Progress in materials development is often paced by the time required to produce and evaluate a large number of alloys with different chemical compositions. This applies especially to refractory high-entropy alloys (RHEAs), which are difficult to synthesize and process by conventional methods. To evaluate a possible way to accelerate the process, high-throughput laser metal deposition was used in this work to prepare a quinary RHEA, TiZrNbHfTa, as well as its quaternary and ternary subsystems by in-situ alloying of elemental powders. Compositionally graded variants of the quinary RHEA were also analyzed. Our results show that the influence of various parameters such as powder shape and purity, alloy composition, and especially the solidification range, on the processability, microstructure, porosity, and mechanical properties can be investigated rapidly. The strength of these alloys was mainly affected by the oxygen and nitrogen contents of the starting powders, while substitutional solid solution strengthening played a minor role.

additive manufacturing↗
DOE OSTI2019

Anisotropy and orbital moment in Sm-Co permanent magnets

Structural and magnetic properties of iron-free and iron-substituted SmCo 5 have been investigated theoretically and experimentally. The nanocrystalline ribbons of SmCo 5–x Fe x (0 ≤ x ≤ 2), which were produced by rapid solidification, crystallize in the hexagonal CaCu5 structure for x ≤ 0.75. Small Fe additions (x = 0.25) substantially improve the coercivity, from 0.45 to 2.70 T, which we interpret as combined intrinsic and extrinsic effect. Most of our findings are consistent with past samarium-cobalt research, but some are at odds with findings that have seemingly been well established through decades of rare-earth transition-metal research. In particular, our local spin-density approximation with Hubbard parameter calculations indicate that the electronic structure of the Sm atoms violates Hund's rules and that the orbital moment is strongly quenched. Possible reasons for the apparent disagreement between theory and experiment are discussed. Here, we explicitly determine the dependence of the Sm 4$f$ charge distribution, arguing that an accurate density-functional description of SmCo 5 is a challenge to future research.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2023

Molecular dynamics simulation of Fe-Si alloys using a neural network machine learning potential

Interatomic potential development using machine learning (ML) approaches has attracted a lot of attention in recent years because these potentials can effectively describe the structural and dynamical properties of complex materials at the atomistic level. Here, in this work, we present the development of a neural network (NN) deep ML interatomic potential for Fe-Si alloys, and we demonstrate the effectiveness of the NN-ML potential in predicting the structures and energies of liquid and crystalline phases of Fe-Si alloys in comparison with the results from ab initio molecular dynamics simulations or experimental data. The developed NN-ML potential is also used to perform molecular dynamics simulations to study the structures of Fe-Si alloys with various compositions under rapid solidification conditions. The short-ranged orders in the rapidly solidified Fe-Si alloys are also analyzed by a cluster alignment method.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Thermodynamic properties of MgSiO 3 at super-Earth mantle conditions

Recent discoveries of terrestrial exoplanets distant from our solar system motivate laboratory experiments that provide insight into their formation and thermal evolution. Using laser-driven shock wave experiments, we constrain high-temperature and high-pressure adiabats and the equation of state of MgSiO 3 ,a dominant mantle constituent of terrestrial exoplanets. Critical to the development of a habitable exoplanet is the early thermal history, specifically the formation and freezing of the magma ocean and its role in enabling convection in the mantle and core. We measure the adiabatic sound speed and constrain the melt transition along the Hugoniot and find that the adiabats and melt boundary of silicate magmas are shallower than predicted. In conclusion, this suggests that small changes in the temperature of a super-Earth mantle would result in rapid melting and solidification of nearly the entire mantle.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2017

Compression Freezing Kinetics of Water to Ice VII

Time-resolved x-ray diffraction (XRD) of compressed liquid water shows transformation to ice VII in 6 nsec, revealing crystallization rather than amorphous solidification during compression freezing. Application of classical nucleation theory indicates heterogeneous nucleation and one-dimensional (e.g., needlelike) growth. In conclusion, these first XRD data demonstrate rapid growth kinetics of ice VII with implications for fundamental physics of diffusion-mediated crystallization and thermodynamic modeling of collision or impact events on ice-rich planetary bodies.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Overcoming the Time Limitation in Molecular Dynamics Simulation of Crystal Nucleation: A Persistent-Embryo Approach

The crystal nucleation from liquid in most cases is too rare to be accessed within the limited time scales of the conventional molecular dynamics (MD) simulation. Here, we developed a “persistent embryo” method to facilitate crystal nucleation in MD simulations by preventing small crystal embryos from melting using external spring forces. We applied this method to the pure Ni case for a moderate undercooling where no nucleation can be observed in the conventional MD simulation, and obtained nucleation rate in good agreement with the experimental data. Moreover, the method is applied to simulate an even more sluggish event: the nucleation of the B2 phase in a strong glass-forming Cu-Zr alloy. The nucleation rate was found to be 8 orders of magnitude smaller than Ni at the same undercooling, which well explains the good glass formability of the alloy. In conclusion, our work opens a new avenue to study solidification under realistic experimental conditions via atomistic computer simulation.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Nanosecond Freezing of Water at High Pressures: Nucleation and Growth near the Metastability Limit

The fundamental study of phase transition kinetics has motivated experimental methods toward achieving the largest degree of undercooling possible, more recently culminating in the technique of rapid, quasi-isentropic compression. This approach has been demonstrated to freeze water into the high-pressure ice VII phase on nanosecond timescales, with some experiments undergoing heterogeneous nucleation while others, in apparent contradiction, suggest a homogeneous nucleation mode. We show through a combination of theory, simulation, and analysis of experiments that these seemingly contradictory results are in agreement when viewed from the perspective of classical nucleation theory. We find that, perhaps surprisingly, classical nucleation theory is capable of accurately predicting the solidification kinetics of ice VII formation under an extremely high driving force ( | Δ μ / k B T | ≈ 1 ) but only if amended by two important considerations: (i) transient nucleation and (ii) separate liquid and solid temperatures. Finally, this is the first demonstration of a model that is able to reproduce the experimentally observed rapid freezing kinetics.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2019

Growth interactions between icosahedral quasicrystals

We investigate the solidification pathways of a population of icosahedral quasicrystals in a liquid through in situ synchrotron x-ray tomography. The wealth of three-dimensional space- and time-resolved data enables us to test the predictions of various models and theories of crystallization on a quasi-crystal-forming alloy. Remarkably, we find the general evolution equation—that accounts for the competing effects of growth, coalescence, and coarsening—fits well our experimental data on surface area concentration. Furthermore, we quantify the orientation selection, screening length, and coarsening rate of the dodecahedra, and compare these results to that of periodic crystals. The latter is a full order of magnitude smaller than that of elemental metal dendrites in the limit of zero volume fraction, a reflection of the low solid-liquid interfacial energy of the icosahedral phase. Furthermore, our paper provides the critical input data for microstructural models used for integrated computational materials engineering of complex intermetallics, including quasicrystals.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effects of Al and Fe solubility on the magnetofunctional properties of $\mathrm{AlFe_2B_2}$

Bridgman single-crystal growth of $\mathrm{AlFe_2B_2}$ resulted in systematic Fe-Al lattice site substitution in the $\mathrm{AlFe_2B_2 (Mn_2AlB_2}$ -type structure, aka $\mathrm{1 - 2 - 2}$) phase along the direction of solidification. The Fe:Al ratio varied from 1.94 to 2.06. The $\mathrm{1 - 2 - 2}$ phase lattice parameters, magnetic transition temperatures ($T_t$) $\mathrm{280 - 315}$ K, magnetic entropy changes ($Δ S$) $\mathrm{2.3 - 4.0 J / kg K}$, heat capacity ($C_p$) $\mathrm{117 - 147 J / mol K}$, and thermal conductivity ($κ$) $\mathrm{~ 2.4 - 11.5 W / m K}$ all varied monotonically across the region of solubility. These findings confirm the sensitivity of the magnetic and thermal properties of the $\mathrm{AlFe_2B_2}$ compound to antisite defects. The interplay between Al and Fe lattice site occupancy and the resultant magnetic and electronic responses facilitates tailoring the properties of the $\mathrm{AlFe_2B_2}$ system for potential functional applications, including magnetic cooling.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Thermally induced structural competitiveness and metastability of body-centered-cubic iron under nonequilibrium conditions

The structure and stability of iron near melting at multi-megabar pressures are of significant interest in high pressure physics and earth and planetary sciences. While the body-centered cubic (BCC) phase is generally recognized as unstable at lower temperatures, its stability relative to the hexagonal close-packed (HCP) phase at high temperatures (approximately 0.5 eV) in the Earth’s inner core (IC) remains a topic of ongoing theoretical and experimental debate. Motivated by a series of studies attempting to understand the state of the IC and resulting in contradictory findings, we aim to explore the physical factors that may contribute to this confusion in a broader context. Our ab initio calculations show a significant drop in energy, the emergence of a plateau and a local minimum in the potential energy surface, and stabilization of all phonon modes of BCC iron at elevated electron temperatures (>1–1.5 eV). These effects increase the competition among the BCC, HCP, and the face-centered cubic (FCC) phases and lead to the metastability of the BCC structure. Furthermore, at pressure-temperature conditions relevant to the IC, we can expect substantial coexistence of FCC and HCP iron due to their similar free energies and low transition barrier (∼0.2 eV/atom), and the thermodynamic stability of BCC iron is enhanced by its substantial lattice vibration entropy. In conclusion, these findings provide a clear theoretical framework for understanding iron phase relations and solidification processes, both experimentally and in the IC.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2026

Parity breaking at faceted crystal growth fronts during ice templating

Directional solidification of water-based solutions has emerged as a versatile technique to template hierarchical porous materials, but this nonequilibrium process remains incompletely understood. Here, in this study, we use phase-field simulations to shed light on the mechanism that selects the growth direction of the lamellar ice structure that templates those materials. Our results show that this selection can be understood within the general framework of spontaneous parity breaking, yielding quantitative predictions for the tilt angle of lamellae with respect to the thermal axis. The results provide a theoretical basis to interpret a wide range of experimental observations.

Materials science↗
DOE OSTI2018

A compact and flexible induction furnace for in situ X-ray microradiograhy and computed microtomography at Elettra: design, characterization and first tests

A compact and versatile induction furnace for in situ high-resolution synchrotron and laboratory hard X-ray microradiography and computed microtomography is described. The furnace can operate from 773 to 1723 K. Its programmable controller enables the user to specify multiple heating and cooling ramp rates as well as variable dwell times at fixed temperatures allowing precise control of heating and cooling rates to within 5 K. The instrument can work under a controlled atmosphere. Thanks to the circular geometry of the induction coils, the heat is homogeneously distributed in the internal volume of the graphite cell ( ca . 150 mm 3 ) where the sample holder is located. The thermal gradient within the furnace is less than 5 K over a height of ca . 5 mm. This new furnace design is well suited to the study of melting and solidification processes in geomaterials, ceramics and several metallic alloys, allowing fast heating (tested up to 6.5 K s -1 ) and quenching (up to 21 K s -1 ) in order to freeze the sample microstructure and chemistry under high-temperature conditions. The sample can be held at high temperatures for several hours, which is essential to follow phenomena with relatively slow dynamics, such as crystallization processes in geomaterials. The utility of the furnace is demonstrated through a few examples of experimental applications performed at the Elettra synchrotron laboratory (Trieste, Italy).

Kudrna Prašek, Marko↗
DOE OSTI2025

High-resolution in-situ characterization of laser powder bed fusion via transmission X-ray microscopy at X-ray free electron lasers

In this work, we describe the instrumentation used to perform the first operando transmission X-ray microscopy (TXM) and simultaneous X-ray diffraction of laser melting simulating laser powder bed fusion on the XCS instrument at the Linac Coherent Light Source (LCLS) X-ray free-electron laser (XFEL). Our TXM with 40× magnification in the X-ray regime at 11 keV gave spatial resolutions down to 940 nm per line pair, with effective pixel sizes down to 206 nm, image integration times of <100 fs, and frame rates tunable between 2.1 and 119 ns for two probe frames (0.48 GHz to 8.4 MHz). Images were recorded on Zyla and Icarus (UXI) detectors to trade off between spatial resolution and time dynamics. A 1 kW CW IR laser was coupled into the interaction point to conduct pump–probe studies of laser melting and solidification dynamics. Our temporal and spatial resolution with attenuation-based contrast exceeds that currently possible with synchrotron-based high-speed radiography. This system was sensitive to feature velocities of 10–12000 m s −1 but we did not observe any motion in this range in the laser melting of Al6061 alloy. Shockwaves were not observed and hot cracking proceeded at velocities below the detection limits. Pore accumulation was observed between successive shots, indicating that bubble escape mechanisms were not active. With proper experimental design, the spatial resolution, contrast and field of view could be further improved or modified. The increased brightness and narrower bandwidth of the XFEL allowed for this imaging technique and it lays the groundwork for a wide range of operando techniques to study additive manufacturing.

47 OTHER INSTRUMENTATION↗