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At least 109 records · Page 6

Automated J-R Curve Analysis Based on the ASTM E1820 Normalization Method

The J-integral vs. crack growth resistance curve (J-R curve) is a useful tool for evaluating material fracture toughness in the ductile condition. A widely accepted practice for conducting tests to obtain J-R curves is ASTM standard E1820, in which the normalization method was introduced as an alternative method for determining the J-R curve. The normalization method requires solely force-displacement data, together with initial and final crack size measurements from a specimen to derive the J-R curve. Because of the elimination of the compliance measurement, the normalization method significantly simplifies testing requirements to obtain J-R curve. Despite these advantages, the analysis procedures of the normalization method are quite complicated to follow, which may limit the wide application of this method. To address this, we have developed a software with user-friendly graphic interface to perform automated normalization analysis. Any users, even without detailed knowledge of the normalization analysis, can use this software to derive J-R curves based on the ASTM E1820 normalization method.

Chen, Xiang↗

Equibiaxial Flexure Strength of a Superfine-Grained Nuclear Graphite

The strength of advanced graphite is reported in accordance with ASTM D7846-16 using a two-parameter Weibull distribution for uniaxial strength testing. The rule of thumb for Weibull distributions is to use a minimum of 30 strength measurements to have a high level of confidence in the Weibull characteristic strength and the Weibull modulus. These large sample sets for statistical confidence are easily obtained for as-manufactured graphite, but determination of the Weibull two-factor parameters on graphite that has been exposed to neutron irradiation is nearly impossible due to irradiation testing restraints on specimen size and space limitations in test reactors for the accommodation of specimens. These restrictions have resulted in irradiation programs that use sub-sized specimens to measure uniaxial strength change, but the specimen geometries still hinder the number of replicate specimens for each irradiation condition. In contrast, this work used an advanced ceramic standard, ASTM C1499-05, as the foundation for equibiaxial strength testing of a superfine-grained nuclear graphite to investigate the irradiation-induced strength change and any changes to the two-parameter Weibull distribution. The goal was to investigate the effect of specimen size on the two-parameter Weibull distribution parameters in support of the small specimens and geometry desired for irradiation. A study of the effect of a reduced sample population was also undertaken to investigate the reliability of using the two-parameter Weibull distribution to study changes to the materials properties caused by neutron irradiation damage. The results of this work suggest that these equibiaxial specimens would be ideal for statistically significant studies of the effects of irradiation on the Weibull characteristic strength (but not the modulus) and for providing a method for surveillance specimen campaigns for future operating commercial reactors.

Campbell, Anne↗

Outgassing of casted and 3D printed silicones

Outgassing of 3D printed and casted silica-filled silicones was studied using a standard ASTM E-595 procedure and a modified Soreq’s method that allows very sensitive measurements of the outgassing kinetics even at low temperatures, 20 – 50 °C. We studied three different silica-filled silicones, non-porous cased M9787, and 3D printed LL50 and 40P materials. The present report shows that vacuum outgassing products of polysiloxane-based materials include multiple species. In addition to chemisorbed and physisorbed water outgassing, previously studied by TPD, polymer fragments of varying sizes evaporate as well. The chemical composition of the condensable volatile species collected on a Germanium substrate, was analyzed by FTIR. It was shown that all studied materials produce mostly PDMS-based outgassing products that form stable droplet-like structure on the Ge substrate. The highest amount of the condensable volatile species was measured for LL50. Isothermal TGA in nitrogen atmosphere of the LL50 material was compared to the standard vacuum outgassing. The results of TGA showed lower mass loss and higher water regain. The kinetics of the outgassing at relatively low temperatures of 20, 30 and 50 °C was studied using Thermoelectric Quartz Crystal Microbalance (TQCM). The TQCM surface was held at -10 °C to enhance condensation of the outgassed moisture. The analysis presented here, when combined with the extensive previous work on moisture outgassing, provides a better understanding of the aging mechanism of polysiloxane-based materials. In this work we show that outgassing techniques, usually applied for qualification of polymers for space-related applications, may be used as a complementary method to study thermal degradation and aging of silica-based silicones. Our results indicate that the long-term degradation mechanics and thermal degradation products depend primarily on the chemical composition of silicone-based material and only slightly affected by the manufacturing process. Surprisingly, the surface-to-volume ratio of the 3D printed vs. casted/molded materials showed only minor effect on the outgassing kinetic parameters.

36 MATERIALS SCIENCE↗

Sustainable Graphite and Jet Fuel from Biorefinery Residue

Abstract Battery‐grade graphite and aviation fuel are traditionally produced from non‐renewable, fossil carbon feedstocks and result in substantial greenhouse gas emissions. Biomass holds exciting potential as a renewable and sustainable feedstock for the production of graphite and aviation fuel, but challenges exist including the necessity of a catalyst when producing graphite and low selectivity when producing aviation fuel. A process to convert a biomass‐derived feedstock into graphite without the use of a catalyst and fuels with high selectivity towards sustainable aviation fuel (SAF) is innovated. Heavy bio‐oil undergoes a conversion process similar to the commercial production of synthetic graphite including coking at 500 °C, calcination at 1000 °C, and graphitization at 2800 °C. The resulting biographite exhibits excellent performance in lithium‐ion battery configurations with specific capacity of ~330 mAh g −1 and a 96.8 % capacity rebound after high rate cycling. The liquid hydrocarbon co‐product from coking is suitable for hydrotreating into SAF. The aviation fuel fraction (70 wt % of the fuel produced) meets ASTM standards and is composed primarily of cycloalkanes (~80 wt %) which improves energy density compared to paraffins produced by other SAF pathways and may replace aromatics for elastomer swelling in traditional jet fuel with less soot production.

09 BIOMASS FUELS↗

Isolation and Characterization of Cellulose Micro/Nanofibrils from Douglas Fir

Cellulose micro/nanofibrils were successfully extracted from softwood Douglas fir in three distinct stages. Initially raw Douglas fir wood chips were subjected to a hot water extraction (HWE) treatment. Then HWE treated cellulosic fibers underwent a bleaching process followed by a mild ultrasonication. Chemical composition analysis according to ASTM standards confirmed that most of hemicelluloses and nearly all lignin were removed during the first two stages, respectively. Microscopy studies showed formation of nanofibrils during the ultrasonication process, and increasing ultrasonication time led to generation of greater percentage of nanofibrils. With the removal of the matrix materials, the crystallinity of the cellulosic fibers was increased, whereas thermal stability was maintained. HWE opened up the cell wall structure, thereby facilitating the subsequent fractionation into micro/nanofibrils. The obtained cellulose micro/nanofibrils could serve as reinforcing material in composite products or raw material for other applications, such as filtration membrane.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Fabrication and Testing of Soy-Based Polyurethane Foam for Insulation and Structural Applications

This study is focused on the fabrication and evaluation of polyurethane (PU) foam fabricated using soy-based polyol that can potentially replace conventional petroleum-based PU foam for thermal applications. Rigid soy-based PU foam samples investigated in this study were produced by copolymerization of diisocyanate with soy-based polyol in presence of Xiameter X0193 surfactant, dibutyltin dilaurate (DBTL) as a catalyst, and water as a blowing agent. Different formulations with varying amounts of blowing agent and catalyst were investigated to optimize the mechanical and thermal properties of soy-based PU foam when compared to commercial petroleum-based foam as a control sample. The prepared samples were tested for density, compressive strength, thermal conductivity, tensile strength, dimensional stability, and thermal stability using the ASTM standards. The cellular structure of the fabricated foam samples was investigated using scanning electron microscopy. It was observed that an increase in density leads to a decrease in insulation. Overall, soy-based foams exhibited similar thermal conductivity as compared to petroleum-based foams.

36 MATERIALS SCIENCE↗

Long Term Creep Behavior of a CoCrFeNiMn High Entropy Alloy

The potential of high entropy alloys (HEAs) to meet or exceed austenitic stainless-steel performance with the additional benefit of improved hot corrosion/oxidation resistance makes FCC HEAs attractive for use in energy applications. While shorter term creep tests have been reported in the literature on HEAs, not all methodologies utilize repeatable techniques. This manuscript reports on over 23,500 accumulated hours of tensile creep testing with adherence to ASTM standards on a melt solidified ingot of CoCrFeNiMn HEA converted to wrought plate using conventional thermo-mechanical processing techniques. The typical standard creep analyses are reported, i.e., Larson-Miller parameter, Monkman-Grant relationship, activation energy for creep, and creep stress exponents were calculated and compared to previously reported short-term creep tests. Additionally, characteristics of creep fracture and microstructural evolution are reported with cursory dislocation mechanisms investigated.

Rozman, Kyle A.↗

Long-Term Creep Behavior of a CoCrFeNi Medium-Entropy Alloy

We report that current research shows that high-entropy alloys (HEAs) can offer superior oxidation resistance compared to more traditional austenitic stainless steels with equivalent tensile mechanical performance. While many reports have been published on creep of CoCrFeNiMn, few focus on the CoCrFeNi family of low to medium entropy alloys. In this manuscript, uniaxial tensile creep test results for more than 46,000 accumulated hours are presented on the equiatomic CoCrFeNi alloy. The alloy was manufactured at NETL using a vacuum induction melt solidification approach with a computationally designed homogenization cycle. After completing the homogenization cycle, the ingot was first hot forged and then hot rolled into 10 mm thick plate, a product form that is relevant to many industries. Creep tests were performed in the temperature range of 600-650 °C using applied stresses from 120 to 189 MPa. This study builds upon previous results on the CoCrFeNiMn family of high-entropy alloys and offers a modicum of clarification about performance compared to small button melts by using ASTM standard test procedures and mechanical test specimens. The apparent creep activation energy and creep stress exponent were similar to those for CoCrFe medium-entropy and CoCrFeNiMn high-entropy alloys. The post-test creep microstructure showed some Cr segregation, which has also been noted for other CoCrFe alloys. The CoCrFeNi alloy also presents a double minimum or two minimum creep rate phenomena.

36 MATERIALS SCIENCE↗

Characterization of fatigue crack growth behavior in LENS fabricated Ti-6Al-4V using high-energy synchrotron x-ray microtomography

Laser Engineered Net Shaping (LENS) is an additive manufacturing technique that belongs to the ASTM standardized directed energy deposition category. To date, very limited work has been conducted towards understanding the fatigue crack growth behavior of LENS fabricated materials, which hinders the widespread adoption of this technology for high-integrity structural applications. In this study, the propagation of a 20 μm initial crack in LENS fabricated Ti-6Al-4V was captured in-situ, using high-energy synchrotron x-ray microtomography. Fatigue crack growth (FCG) data were then determined from 2D and 3D tomography reconstructions, as well as from fracture surface striation measurements using SEM. The generated data were compared to those obtained from conventional FCG tests that used compliance and direct current potential drop (DCPD) techniques to measure long and small crack growth. In conclusion, the observed agreement demonstrates that x-ray microtomography and fractographic analysis using SEM can be successfully combined to study the propagation behavior of fatigue cracks.

36 MATERIALS SCIENCE↗

Ethanolysis of camelina oil under supercritical condition with hexane as a co-solvent

Non-catalytic transesterification of camelina sativa oil under supercritical ethanol (SCE) conditions with hexane as a co-solvent was investigated to study the fatty acid ethyl ester (FAEE) yields. This process enables simultaneous transesterification of triglycerides and ethyl esterification of fatty acids in a shorter reaction of time and may reduce the energy consumption due to simplified separation and purification steps. It was found that the co-solvent plays a vital role in reducing the severity of critical operational parameters and maximizes the biodiesel yield. The important variables affecting the ethyl ester yield during the transesterification reaction are the molar ratio of alcohol/oil, reaction time, reaction temperature and co-solvent to oil ratio. Camelina biodiesel samples were analyzed using FT-IR, GC-MS and hermogravimetric analysis (TGA) methods. The fuel properties of camelina biodiesel produced were compared with those of the regular diesel and found to be conforming to the American Society for Testing and Materials (ASTMs) standards.

09 BIOMASS FUELS↗

UR 2 : Ultra-rapid reactivity test for real-time, low-cost quality control of calcined clays

To reduce cement's carbon footprint, there is growing interest in commercial adoption of sustainable SCMs such as calcined clays. However, the existing ASTM standard (R 3 test, C1897) to test the reactivity of such clays takes up to 7 days and cannot be used for real-time quality control in an industrial setting. We address this issue by introducing a 5-min Ultra-Rapid Reactivity (UR 2 ) test. By dissolving 47 clay specimens in 4 M NaOH solutions at 90°C, we report that a dissolution index of 1.54Al + Si correlates strongly to the 7-day R 3 heat (R 2 = 0.92, RMSE = 94.1 J/g). This dissolution index also correlates to the 28-day compressive strength for 14 clay mixtures (R 2 = 0.94, RMSE = 1.7 MPa). This UR 2 test relies on colorimetry and can be conducted via off-the-shelf, low-cost cameras. Overall, our new UR 2 test opens a pathway for real-time, low-cost quality control of calcined clays.

36 MATERIALS SCIENCE↗

Artificial neural network based predictions of cetane number for furanic biofuel additives

The next generation of alternative fuels is being explored through advanced chemical and biological production techniques for the purpose of finding suitable replacements for diesel and gasoline while lowering production costs and increasing process yields. Chemical conversion of biomass to fuels offers a plethora of pathways with a variety of fuel molecules, both novel and traditional, which may be targeted. In the search for new fuels, an initial, intuition-driven evaluation of fuel compounds with desired properties is required. Due to the high cost and significant production time needed to synthesize these materials at a scale sufficient for exhaustive testing, a predictive model would allow chemists to preemptively screen fuel properties of potentially desirable fuel candidates. Current work has shown that predictive models, in this case artificial neural networks (ANN's) analyzing quantitative structure property relationships (QSPR's), can predict the cetane number (CN) of a proposed fuel molecule with relatively small error. A fuel's CN is a measure of its ignition quality, typically defined using prescribed ASTM standards and a cetane testing engine. Alternatively, the analogous derived cetane number (DCN), obtained using an Ignition Quality Tester (IQT), is a direct measurement alternative to the CN that uses an empirical inverse relationship to the ignition delay found in the constant volume combustion chamber apparatus. DCN data points acquired using an IQT were utilized for model validation and expansion of the experimental database used in this study. The present report improves on an existing model by optimizing the model architecture along with the key learning variables of the ANN and by making the model more generalizable to a wider variety of fuel candidate types, specifically the class of furans and furan derivatives, by including specific molecules for the model to incorporate. The new molecules considered include tetrahydrofuran, 2-methylfuran, 2-methyltetrahydrofuran, 5,5'-(furan-2-ylmethylene)bis(2-methylfuran), 5,5'-((tetrahydrofuran-2-yl)methylene)bis(2-methyltetrahydrofuran), tris(5-methylfuran-2-yl)methane, and tris(5-methyltetrahydrofuran-2-yl)methane. Model architecture adjustments improved the overall root-mean-square error (RMSE) of the base database predictions by 5.54%. Additionally, through the targeted database expansion, it is shown that the predicted cetane number of the furan-based molecules improves on average by 49.21% (3.74 CN units) and significantly for a few of the individual molecules. This indicates that a selected subset of representative molecules can be used to extend the model's predictive accuracy to new molecular classes. The approach, bolstered by the improvements presented in this paper, enables chemists to focus on promising molecules by eliminating less favorable candidates in relation to their ignition quality.

09 BIOMASS FUELS↗

Design and thermomechanical properties of a γ' precipitate-strengthened Ni-based superalloy with high entropy γ matrix

A novel Ni-based superalloy was designed with γ' precipitate strengthening, controlled γ/γ' lattice misfit and high configurational entropy of the γ matrix for improved high temperature performance up to 800 degrees C. The alloy contains nano-sized γ' precipitates, MC and other grain boundary carbides. Three variants of the alloy were fabricated using vacuum induction melting, a computational-based homogenization cycle for reducing solidification segregation, and thermomechanical processing steps of forging followed by hot rolling to produce plates from which ASTM standard test specimens were extracted. Tensile testing at room temperature and elevated temperatures up to 800 degrees C revealed superior yield stress when compared to Nimonic 105 with good tensile strength values. Furthermore, the three alloys are machinable with maximum stresses comparable to standard practices as determined using deformation mechanisms maps obtained from Gleeble testing and EBSD analysis. Due to the composition of the experimental alloys falling outside the typical range used to populate thermodynamic databases, differences in phase predictions and related temperatures were observed between the experiment and Thermo-Calc predictions. Here, the γ' forming elements Ti and Nb had a similar effect on the γ' precipitates and indirectly contributed to changing the entropy of the γ matrix. Based on the results of this study, these alloys have the potential for use at 800 degrees C in energy structural applications. Definitions related to this novel class of alloys are discussed.

36 MATERIALS SCIENCE↗

Understanding the effect of specimen size on the properties of fine-grain isotropic nuclear graphite for irradiation studies: Physical, electrical, thermal properties

Programs at Oak Ridge National Laboratory are investigating the effects of neutron irradiation in the High Flux Isotope Reactor (HFIR) on properties of fine-grain nuclear graphites. Specimens were irradiated in the HFIR flux trap, which required using specimens that are smaller than the sizes recommended by ASTM standards. Here, this work has investigated whether subsized specimens can be used to reliably determine the measured physical (density, elastic moduli, and electrical resistivity) and thermal properties (coefficient of thermal conductivity and thermal conductivity). The results show the specimen sizes in this investigation had a minimal influence on any of the measured properties. Even for the properties where size influenced the measured value (density and thermal conductivity), an explanation is provided, and the consequences can be accounted for in post-irradiation results. This work demonstrated that using subsized specimens for physical and thermal property measurements is suitable when necessary for fine-grain isotropic graphite.

36 MATERIALS SCIENCE↗

On the improvement of measurement accuracy of retained austenite in steel with X-ray diffraction

Highlights: • Improved procedure to determine austenite in steels with crystallographic texture • Extension to X-ray area detectors • Electropolishing is essential to get correct results. - Abstract: An improved measurement scheme for the determination of the retained austenite fraction with X-ray diffraction is extended to area detectors. The scheme reduces the error due to crystallographic texture in phase analysis of steel by averaging the results of diffraction patterns at different sample positions. The method is based on the standard ASTM E975, but it can be easily extended to other crystal structures, multi-phase materials or X-ray wavelengths. Phase transformation, induced by mechanical sample preparation, may lead to a significant reduction of the retained austenite fraction. Electropolishing before the measurement is beneficial to remove the layer affected by sample preparation.

36 MATERIALS SCIENCE↗

A numerical and experimental approach to compare the effect of sample thickness in small in-situ SEM and large ex-situ tensile testing in Alloy 709

ASTM standards for tensile tests define specific sample size requirements regardless of grain size of the material. However, sample size requirements for testing should be considered in conjunction with the number of grains within its reduced cross-sectional area. This is particularly important for in-situ Scanning Electron Microscope (SEM) tensile tests, as they have to be conducted on smaller samples. In this study, a comprehensive experimental and numerical evaluation of the effect of specimen thickness (and the resulting number of grains within the cross-section) were conducted using in-situ SEM tensile test (on submillimeter thick samples) and ex-situ tensile tests (on samples of 0.68–5.9 mm thickness) and the results are compared with FEM simulations outcome. All tests were conducted at room temperature and the results are correlated to the number of grains within the thickness of specimens. The tensile test results indicated that even though the 0.2% proof stress and the tensile strength do not vary for the current range of thicknesses (with number of grains in the cross-section varying from 13 to 118), a difference in necking mechanism exists. Post tensile strength, thinner samples undergo more shear failure and diagonal localized necking whereas thicker samples experience more diffuse necking indicated by decreased area of shear failure at the edges and increased area of dimpled tensile failure at the center of the sample. Further, FEM results complement the experimental findings by showing the formation of conjugated localized shear bands on the upper and lower surface in the 0.68 mm thick sample and shear bands combining to form singular shear bands in thicker samples. These results also confirm the validity of the in-situ SEM tensile tests conducted on thinner samples as long as the required minimum number of grains exist within the cross-section.

36 MATERIALS SCIENCE↗

Extrusion of Unhomogenized Castings of 7075 Aluminum via ShAPE

Extrusion of unhomogenized castings of 7075 aluminum (Al) alloy has been accomplished using shear assisted processing and extrusion (ShAPE). The simultaneous plastic deformation and heat generation during ShAPE rapidly fracture and dissolve interdendritic and intragranular secondary phases of Al-Zn-Mg-Cu, accomplishing homogenization in seconds rather than many hours in a furnace prior to extrusion. ShAPE thereby eliminates the energy-intensive and time-consuming homogenization step required to prepare as-cast microstructures for conventional extrusion. Concurrently, extensive grain refinement occurs due to gradient activation of dynamic recrystallization during ShAPE, which facilitates a threefold increase in extrusion speed compared to the conventional extrusion method. Evident enhancement of the mechanical properties of ShAPE+T6 samples is achieved, compared to the ASTM standard values for conventional extrusion products. The microstructural evolution pathway, involving the processes of grain refinement and secondary particle dissolution, is explained using scanning and transmission electron microscopy.

36 MATERIALS SCIENCE↗

Linking constituent phase properties to ductility and edge stretchability of two DP 980 steels

Two DP 980 steels were characterized with multiple methods to determine its microstructure characteristics, tensile properties and edge stretchability. The first (DP980-B) is a commercial grade DP980 steel produced by AK Steel, while the second (DP980-T) is a modification of the first one by a tempering process. Both contain two individual phases: ferrite and martensite with body centered cubic (BCC) and tetragonal (BCT) crystal structure respectively. ASTM standard tensile tests were performed for both materials, revealing that DP980-B has higher work hardening and larger total elongation than DP980-T. Standard hole piercing and subsequent hole expansion and extrusion tests were also performed. The critical hole expansion ratio (HER) of hole pierced sheet at different nominal clearances, on the other hand, show an opposite trend: the HER of DP980-T almost doubles that of DP980-B. This indicates the tensile ductility and edge stretchability are determined by different mechanisms due to different deformation modes. The ductility of sheet metal during uniaxial tension is determined by deformation instability, i.e. necking, due to less constraint at the region of deformation and fracture will occur quickly after necking. The contribution of post-necking deformation to the total elongation is insignificant for the high strength grades such as DP980 steels. The ductility during hole-expansion, however, is mainly determined by material fracture behavior that is dependent on phase property disparity and material intrinsic fracture parameters. With the individual phase properties for both DP steels determined by in situ tensile tests under high energy X-ray diffraction, the results show that DP980-T steel has lower property disparities between the two phases than DP980-B steel, due to the tempering process. This explains why the DP980-T steel has higher HER than DP980-B steel: lower phase disparity will lead to less local deformation during loading. The higher work hardening rate for DP980-B steel contributes to its higher uniform elongation compared with DP980-T steel based on the maximum load condition of deformation instability. An integrated finite element simulation framework for studying hole expansion is also presented here, based on the calculated individual phase properties from the combined high energy x-ray diffraction (HEXRD) and elastic plastic self-consistent modeling. The simulation results correlate well with the experimental results on the HER difference between the two materials.

36 MATERIALS SCIENCE↗