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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 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Potassium-Containing α-MnO 2 Nanotubes: The Impact of Hollow Regions on Electrochemistry

α-MnO 2 type materials have been studied as electrode materials in rechargeable batteries and electrocatalysts due to their 2 × 2 tunneled crystal structures capable of accommodating cations and their tunable physiochemical properties. In this study, we deliberately synthesized K + containing α-MnO 2 (K 0.9 Mn 8 O 16 ) hollow nanotubes varying the dimensions of the hollow regions and level of surface defects. The K 0.9 Mn 8 O 16 nanotube material samples have similar crystallinity, thermal stability, and average Mn oxidation state. Oxygen surface defects in the hollow regions were revealed through detailed studies using electron energy loss spectroscopy. The impact of the hollow regions and associated surface defects on the electrochemistry of K x Mn 8 O 16 were investigated using cyclic voltammetry, galvanostatic intermittent titration technique, and galvanostatic cycling. The K 0.9 Mn 8 O 16 nanotubes with a large hollow region (~30 nm) and higher level of surface defects show higher apparent lithium ion diffusion coefficients and lower polarization compared to the nanotubes with a small hollow region (~10 nm). In-situ lithiation demonstrated that the dimensions of the nanotube walls expanded, but the hollow region did not change in size as result of lithiation. Furthermore, this research demonstrates that tuning particle architecture and surface defects can positively impact functional behavior of electrochemical storage materials.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2020

Detection of large extracellular silver nanoparticle rings observed during mitosis using darkfield microscopy

During studies on the absorption and interactions between silver nanoparticles and mammalian cells grown in vitro it was observed that large extracellular rings of silver nanoparticles were deposited on the microscope slide, many located near post-mitotic cells. Silver nanoparticles (AgNP, 80nm), coated with citrate, were incubated at concentrations of 0.3 to 30 μg/ml with a human-derived culture of retinal pigment epithelial cells (ARPE-19) and observed using darkfield and fluorescent microscopy, 24 h after treatment. Approximately cell-sized extracellular rings of deposited AgNP were observed on the slides among a field of dispersed individual AgNP. The mean diameter of 45 nanoparticles circles was 62.5 +/-12 microns. Ring structures were frequently observed near what appeared to be post-mitotic daughter cells, giving rise to the possibility that cell membrane fragments were deposited on the slide during mitosis, and those fragments selectively attracted and retained silver nanoparticles from suspension in the cell culture medium. These circular structures were observable for the following technical reasons: 1) darkfield microscope could observe single nanoparticles below 100 nm in size, 2) a large concentration (10 8 and 10 9 ) of nanoparticles was used in these experiments 3) negatively charged nanoparticles were attracted to adhesion membrane proteins remaining on the slide from mitosis. The observation of silver nanoparticles attracted to apparent remnants of cellular mitosis could be a useful tool for the study of normal and abnormal mitosis.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2021

On the scaling of wind turbine rotors

This paper formulates laws for scaling wind turbine rotors. Although the analysis is general, the article primarily focuses on the subscaling problem, i.e., on the design of a smaller-sized model that mimics a full-scale machine. The present study considers both the steady-state and transient response cases, including the effects of aerodynamic, elastic, inertial, and gravitational forces. The analysis reveals the changes to physical characteristics induced by a generic change of scale, indicates which characteristics can be matched faithfully by a subscaled model, and states the conditions that must be fulfilled for desired matchings to hold. Based on the scaling laws formulated here, the article continues by considering the problem of designing scaled rotors that match desired indicators of a full-scale reference. To better illustrate the challenges implicit in scaling and the necessary tradeoffs and approximations, two different approaches are contrasted. The first consists in a straightforward geometric zooming. An analysis of the consequences of zooming reveals that, although apparently simple, this method is often not applicable in practice, because of physical and manufacturing limitations. This motivates the formulation of scaling as a constrained optimal aerodynamic and structural matching problem of wide applicability. Practical illustrations are given considering the scaling of a large reference 10 MW wind turbine of about 180 m in diameter down to three different sizes of 54, 27, and 2.8 m. Results indicate that, with the proper choices, even models characterized by very significant scaling factors can accurately match several key performance indicators. Additionally, when an exact match is not possible, relevant trends can at least be captured.

17 WIND ENERGY↗
DOE OSTI2024

Effect of 60 Co Irradiation on Boehmite Dissolution in Caustic Solutions

Here, in this work, we examine how radiation impacts the dissolution behavior of boehmite by subjecting dry nanoparticles of different sizes to 60 Co γ radiation and subsequently analyzing their dissolution behavior in caustic solutions as a function of temperature. The measured kinetics show that irradiation with an amount 228.24 Mrad significantly slows the dissolution rate, particularly for smaller sizes at lower temperatures. Specifically, the temperature-dependent dissolution rates of irradiated 20 nm boehmite versus pristine material in 3 M NaOH solutions were several times lower (e.g., rate constant of 0.026 vs 0.075 h –1 at 60 °C), with an apparent activation energy 40 kJ mol –1 higher. Although various imaging techniques and X-ray diffraction measurements consistently revealed no obvious differences between pristine and irradiated samples, after irradiation significant binding energy shifts were detected in the X-ray photoelectron Spectroscopy peaks of Al 2p and O 1s, and a change in their relative intensities indicated a lower O/Al ratio. This suggests that γ-irradiation may stabilize boehmite particle surfaces by driving their chemistry and structure toward more stable aluminum oxide forms. This finding may help explain slower dissolution rates of boehmite in nuclear waste and may be useful for the development of more robust predictive models and effective strategies for waste processing.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2020

Pulsed Thermal Tomography Nondestructive Examination of Additively Manufactured Reactor Materials (Second Annual Progress Report)

Additive manufacturing (AM) is an emerging method for cost-efficient fabrication of nuclear reactor parts. AM of metallic structures for nuclear energy applications is currently based on laser powder bed fusion (LPBF) process, which can introduce internal material flaws, such as pores and anisotropy. Integrity of AM structures needs to be evaluated nondestructively because material flaws could lead to premature failures due to exposure to high temperature, radiation and corrosive environment in a nuclear reactor. Thermal tomography (TT) provides a capability for non-destructive evaluation of sub-surface defects in arbitrary size structures. Thermal tomography is a computational method for heat diffusion-based imaging of solids, which provides 3D visualization of data from flash thermography measurements. We investigate thermal tomography imaging and nondestructive evaluation of stainless steel and nickel super alloy metallic structures produced with laser powder bed fusion (LPBF) additive manufacturing (AM) process. Metallic structures produced with LPBF contain defects, and there are limited capabilities to evaluate these structures non-destructively. Thermal tomography reconstruction of 3D apparent spatial effusivity provides information about AM structure geometry and internal material flaws. We study performance of thermal tomography in imaging of metallic structures through COMSOL computer simulations of transient heat transfer, and through reconstruction of data obtained from experimental measurements. Reconstruction of internal defects is investigated using a stainless steel 316L specimen with flat bottom hole (FBH) indentations, and Inconel 718 plate produced with laser powder bed fusion (LPBF) method, which contains imprinted hemispherical shape low density regions containing non-sintered metallic powder. The FBH’s have the same sizes as the imprinted defects in the LPBF specimens, but offer better imaging contrast. Thermal tomography reconstructions provide visualizations of internal defects, and allow for estimation of their sizes and locations. Detection sensitivity of TT is limited by noises. We investigate separation of signal from noise in thermography images using several machine learning (ML) methods, including new spatio-temporal blind source separation (STBSS) and spatio-temporal sparse dictionary learning (STSDL) methods. Performance of the ML methods is benchmarked using thermography data obtained from imaging stainless steel 316L and Inconel 718 specimens produced LPBF method with imprinted calibrated porosity defects. The ML methods are ranked by F-score and execution runtime. Finally, we investigate TT of AM stainless steel 316L specimen with imprinted internal porosity defects using relatively low-cost, small form factor infrared (IR) camera based on uncooled micro bolometer detector. Sparse coding related K-means singular value decomposition (SVD) machine learning, image processing algorithms are developed to improve quality of TT images through removal of Additive white Gaussian noise without blurring the images. Following initial qualification of an AM component for deployment in a nuclear reactor, a compact TT can also be used for in-service nondestructive evaluation (NDE). With capability to perform in-service NDE of the AM component lifecycle, TT data can be used for development of a component digital twin.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Studying the Suitability of Nineteen Lignins as Partial Polyol Replacement in Rigid Polyurethane/Polyisocyanurate Foam

In this study, nineteen unmodified lignins from various sources (hardwood, softwood, wheat straw, and corn stover) and isolation processes (kraft, soda, organosolv, sulfite, and enzymatic hydrolysis) were used to replace 30 wt.% of petroleum-based polyol in rigid polyurethane/polyisocyanurate (PUR/PIR) foam formulations. Lignin samples were characterized by measuring their ash content, hydroxyl content (Phosphorus Nuclear Magnetic Resonance Spectroscopy), impurities (Inductively Coupled Plasma), and pH. After foam formulation, properties of lignin-based foams were evaluated and compared with a control foam (with no lignin) via cell morphology, closed-cell content, compression strength, apparent density, thermal conductivity, and color analysis. Lignin-based foams passed all measured standard specifications required by ASTM International C1029-15 for type 1 rigid insulation foams, except for three foams. These three foams had poor compressive strengths, significantly larger cell sizes, darker color, lower closed-cell contents, and slower foaming times. The foam made with corn stover enzymatic hydrolysis lignin showed no significant difference from the control foam in terms of compressive strength and outperformed all other lignin-based foams due to its higher aliphatic and p-hydroxyphenyl hydroxyl contents. Lignin-based foams that passed all required performance testing were made with lignins having higher pH, potassium, sodium, calcium, magnesium, and aliphatic/p-hydroxyphenyl hydroxyl group contents than those that failed.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2024

Pressureless sintering of lithium hydride

Lithium Hydride is a material of growing importance for addressing technological challenges related to nuclear fusion, long-term human space travel, and thermal energy storage. Pressureless sintering provides a straightforward, scalable approach to produce dense LiH parts of all sizes and shapes. Pressed LiH green compacts were sintered at heating rates from 2.5 to 20 °C/min to 650 °C, yielding densities up to 96 ± 1.4 %, with densification initiating at 500 °C. Here, a validated master sintering curve was constructed with a sintering apparent activation energy of 135 kJ/mol. X-ray diffraction and simultaneous thermal analysis revealed Li 2 O formation from 300 – 550 °C and decomposition of LiH into Li metal at 550 °C, each reflected as deviations in the master sintering curve. Computed tomography after thermal treatment to 550 °C showed the formation of corrosion products, and after thermal treatment to 650 °C LiH reduction to Li most significantly at exposed surfaces.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Soft-mode enhanced type-I superconductivity in LiPd 2 Ge

The synthesis, crystal structure, and physical properties (magnetization, resistivity, heat capacity) in combination with theoretical calculations of the electronic structure and phonon properties are reported for intermetallic compounds LiPd 2 X ( X = Si, Ge, and Sn). LeBail refinement of powder x-ray diffraction data confirms that all compounds belong to the Heusler family (space group $\textit{F m-3m}$, No. 225). The lattice parameter increases with atomic size of X , and its value varies from $\textit{a}$ = 5.9059(4) Å for LiPd 2 Si and $\textit{a}$ = 6.0082(3)Å for LiPd 2 Ge, to $\textit{a}$ = 6.2644(1) Å for LiPd 2 Sn. The first compound, LiPd 2 Si, has apparently not been previously reported. All measured quantities demonstrate that LiPd 2 Ge exhibits superconductivity below $T_c$ = 1.96 K and the normal- and superconducting-state data indicate that it is a weak-strength type-I superconductor ($C/γT_c$ = 1.38) with electron-phonon coupling constant $λ_{e–p}$ = (0.53–0.56). LiPd 2 Si and LiPd 2 Sn are not superconducting above 1.68 K. The experimental observations are supported by theoretical calculations which show that LiPd 2 Ge has the highest computed $λ_{e–p}$ and $T_c$ of the group. A strong softening of the acoustic phonon mode is calculated, and in the case of X = Ge and Sn, imaginary phonon frequencies were computed. In this work, the soft mode is most pronounced in the case of LiPd 2 Ge, which suggests its correlation with superconductivity.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2020

Analysis and improvement of the hot disk transient plane source method for low thermal conductivity materials

The hot disk transient plane source (TPS) method is a widely used standard technique (ISO 22007-2) for the characterization of thermal properties of materials, especially the thermal conductivity, k. Despite its well-established reliability for a wide variety of common materials, the hot disk TPS method is also known to suffer from a substantial systematic errors when applied to low-k thermal insulation materials. Here, we present a combined numerical and experimental study on the influence of the geometry of hot disk sensor on measured value of low-k materials. We demonstrate that the error is strongly affected by the finite thickness and thermal mass of the sensor's insulation layer was well as the corresponding increase of the effective heater size beyond the radius of the embedded metal heater itself. We also numerically investigate the dependence of the error on the sample thermal properties, confirming that the errors are worse in low-k samples. A simple correction function is also provided, which converts the apparent (erroneous) result from a standard hot disk TPS measurement to a more accurate value. A standard polyimide sensor was also optimized using both wet and dry etching to provide more accurate measurement directly. Experimentally corrected value of k for Airloy x56 aerogel and a commercial silica aerogel using the numerical correction factor derived based on the standard TPS sensor is in excellent agreement with the directly measured value from the TPS sensor using the optimized polyimide sensor. Finally, both of these methods can reduce the errors to less than 4% as compared to around 40% error of overestimation from raw values measured with the pristine sensor. Such results show that both the numerical correction to a pristine senor or an optimized sensor are capable of providing highly accurate value of thermal conductivity for such materials.

36 MATERIALS SCIENCE↗
DOE OSTI2022

A concurrent irradiation-mechanics multiscale coupling model

The vast majority of our current knowledge regarding the basic mechanisms controlling irradiation effect on mechanical properties is based almost entirely on the results of post-irradiation experiments or theoretical models. However, the concurrent effects of irradiation, mechanical stress, and thermal damage on the failure phenomena of materials and components remain largely unexplored due to its internal multiscale-multiphysics coupling nature. Here, we present here a concurrent irradiation-mechanics multiscale coupling model. The concurrent evolutions of nanoscale irradiation defect clusters, microscale dislocation configurations, and mechanical responses are well captured based on coupling cluster dynamics, discrete dislocation dynamics, and the finite element methods using an effective time marching scheme. Model predictions of defect densities and size are in general agreement with experimental observations. Irradiation hardening is shown to take place also in samples undergoing concurrent irradiation-mechanical loading, similar to samples tested post-irradiation. However, the occurrence of plastic flow localization and dislocation channel formation is not accompanied with apparent yield drop (softening) under concurrent irradiation-mechanical loading conditions, which is different from the post-irradiation case.

42 ENGINEERING↗
DOE OSTI2025

Entanglement Randomness and Gapped Itinerant Carriers in a Frustrated Quantum Magnet

The quantum spin liquid is a state manifesting extraordinary many-body entanglement, and the material NaYbSe 2 is thought to be one of the most promising candidates for its realization. Through low-temperature heat capacity and thermal conductivity measurements, we identify an apparent contradiction familiar to many quantum spin liquid candidates: While entropy is stored by apparently gapless excitations, the itinerant carriers of entropy are gapped. By studying the compositional series NaYb 𝑥⁢ Lu 1−𝑥⁢ Se 2 across a percolation transition of the magnetic lattice, we suggest that this contradiction can be resolved by the presence of entanglement scales of random sizes. Moreover, as we truncate the scale of entanglement by magnetic dilution, we show that the itinerant magnetic entropy carrier in NaYbSe 2 does not arise from a uniform globally entangled spin ground state but rather materializes through the stochastic propagation of boundaries between locally entangled spin objects.

Lyu, Yuanqi 吕源祺 [University of California, Berkele↗
DOE OSTI2021

A Grand Challenge "Uncertainty Project" to Accelerate Advances in Earth System Predictability: AI-Enabled Concepts and Applications

This proposal is emerging from GISS ModelE3 ESM development in the area of cloud physics, so we begin with an example of research needs/gaps from that work. Here, some of our greatest development concerns arise where we lack fundamental process-level understanding, as in ice formation. Namely, it is currently unclear what is the main process that is forming the majority of ice crystals in commonly occurring convection, apparently via secondary ice production at warm temperatures. We are keenly awaiting laboratory data for candidate mechanisms, which is not yet in hand to crucially establish their efficiency. Our progress is also hampered by a lack of uncertainty characterization in currently available measurements of ice crystal number size distributions. Furthermore, the same multiplication process may be responsible for a majority of ice crystals in many extratropical mixed-phase clouds, whose variable representation in CMIP6 ESMs may be a leading cause of differences in cloud phase feedback and ECS. Yet we have been required to deliver an ESM with the cloud physics knowledge at hand. The proposed grand challenge project is AI-enabled via application of machine learning (ML) to climate model and observational data streams (focal area 3), and applications include AI-guided observing system design and model/component/parameterization selection (areas 1 and 2). The project is structurally agnostic as to whether model or observing system components use AI approaches or not, but uncertainties must be estimated and propagatable in both.

58 GEOSCIENCES↗
DOE OSTI2024

Community Data Contribution to M.E.T.A. with ATF-relevant Hydrided Zr cladding (Coated and Uncoated)

Since the aftermath of the Fukushima Daiichi loss-of-coolant accident, accident-tolerant fuel (ATF) claddings have been developed to improve the coping times in such events. However, the mechanical performance of ATF cladding is crucial in ensuring that it does not negatively impact the mechanical integrity during all other stages of the nuclear fuel cycle, and the validity of the existing safe operating margins must be verified. However, due to the cladding’s tube geometry and textured anisotropy, determination of apparent mechanical properties under certain deformation paths is challenging. In the uniaxial hoop direction, for instance, the measured mechanical stresses include frictional forces caused by loading mandrels or varying deformation paths in the sample during traditional ring tensile testing. This experimental difficulty is exacerbated by the specimen size. However, addressing these challenges enables irradiation separate-effects investigations in which the materials can be inserted in reactors like the High Flux Isotope Reactor, and reducing the material consumption of commercially irradiated material allows for further post-irradiation examinations. Despite the advantages of reduced-scale mechanical testing, any drawbacks from new specimen geometries must be evaluated, and uncertainties from specimen preparation, setup, and analysis methodologies must be understood.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Broad sterile neutrinos & the reactor/gallium tension

Significant evidence exists for the apparent disappearance of electron-type neutrinos in radioactive source experiments. Yet, interpreted within the standard ‘3+1 sterile neutrino scenario’, precision short-baseline measurements of electron antineutrinos from nuclear reactors strongly disagree with these results. Recently, it has been demonstrated that allowing for a finite wavepacket size for the reactor neutrinos can ameliorate such a tension, however the smallness of the required wavepackets is a subject of intense debate. In this work, we demonstrate that a ‘broad’ sterile neutrino may relax this tension in much the same way. Such a phenomenological possibility can arise in plausible hidden sector scenarios, such as a clockwork-style sector, for which we provide a concrete microscopic model.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2024

Crystal-chemical origins of the ultrahigh conductivity of metallic delafossites

Abstract Despite their highly anisotropic complex-oxidic nature, certain delafossite compounds ( e.g ., PdCoO 2 , PtCoO 2 ) are the most conductive oxides known, for reasons that remain poorly understood. Their room-temperature conductivity can exceed that of Au, while their low-temperature electronic mean-free-paths reach an astonishing 20 μm. It is widely accepted that these materials must be ultrapure to achieve this, although the methods for their growth (which produce only small crystals) are not typically capable of such. Here, we report a different approach to PdCoO 2 crystal growth, using chemical vapor transport methods to achieve order-of-magnitude gains in size, the highest structural qualities yet reported, and record residual resistivity ratios ( > 440). Nevertheless, detailed mass spectrometry measurements on these materials reveal that they are not ultrapure in a general sense, typically harboring 100s-of-parts-per-million impurity levels. Through quantitative crystal-chemical analyses, we resolve this apparent dichotomy, showing that the vast majority of impurities are forced to reside in the Co-O octahedral layers, leaving the conductive Pd sheets highly pure (∼1 ppm impurity concentrations). These purities are shown to be in quantitative agreement with measured residual resistivities. We thus conclude that a sublattice purification mechanism is essential to the ultrahigh low-temperature conductivity and mean-free-path of metallic delafossites.

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

Physicochemical Gas–Solid Sorption Properties of Geologic Materials Using Inverse Gas Chromatography

The goal of this study was to determine the physicochemical properties of a variety of geologic materials using inverse gas chromatography (IGC) by varying probe gas selection, temperature, carrier gas flow rate, and humidity. This is accomplished by measuring the level of interaction between the materials of interest and known probe gases. Identifying a material’s physicochemical characteristics can help provide a better understanding of the transport of gaseous compounds in different geologic materials or between different geological layers under various conditions. Our research in this study focused on measuring the enthalpy (heat) of adsorption, Henry’s constant, and diffusion coefficients of a suite of geologic materials, including two soil types (sandy clay-loam and loam), quartz sand, salt, and bentonite clay, with various particle sizes. The reproducibility of IGC measurements for geologic materials, which are inherently heterogeneous, was also assessed in comparison to the reproducibility for more homogeneous synthetic materials. This involved determining the variability of physicochemical measurements obtained from different IGC approaches, instruments, and researchers. For the investigated IGC-determined parameters, the need for standardization became apparent, including the need for application-relevant reference materials. The inherent physical and chemical heterogeneities of soil and many geologic materials can make the prediction of sorption properties difficult. Characterizing the properties of individual organic and inorganic components can help elucidate the primary factors influencing sorption interactions in more complex mixtures. This research examined the capabilities and potential challenges of characterizing the gas sorption properties of geologic materials using IGC.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

A Pn magnitude scale m b ( Pn ) for earthquakes along the equatorial Mid-Atlantic Ridge

We developed a short-period Pn magnitude scale m b (Pn) for earthquakes along the equatorial Mid-Atlantic Ridge. Due to low signal-to-noise ratios, teleseismic body wave magnitude and long-period surface wave magnitude cannot be confidently determined for small earthquakes of m b < 4. Local magnitude scales are also not useful for these events because the oceanic environment does not allow the propagation of crustal phases. However, regional high-frequency Pn waves from these small- to moderate-size (m b 3–6) earthquakes are well recorded in the equatorial Atlantic region and can be used to assign magnitudes. We measured over 2041 Pn peak amplitudes on vertical records from about 21 stations in northeastern Brazil and 11 stations in western Africa in the distance range of 700–3700 km. We analysed data from 189 events from the global centroid moment tensor catalogue to tie our m b (Pn) scale to M w so that seismic moments can be readily estimated. Pn arrivals show apparent group velocity between 7.9 km s –1 at short ranges (~1000 km) and up to 9.1 km s –1 at 3500 km. The measured peak amplitudes have a frequency between 0.8 and 3 Hz at 1000–1800 km, but at greater distances, 1800–3700 km, they show a remarkably consistent frequency of about 0.8 Hz. The peak amplitude attenuates at a higher rate at short distances (~0.65 magnitude units between 700 and 2000 km) but attenuates at a lower rate at long distances (~0.35 magnitude units between 2000 and 3700 km). The low rate of amplitude decay with distance and nearly constant frequency content of the peak amplitudes suggest that Pn waves propagate efficiently in the lower part of the upper mantle in the equatorial Atlantic Ocean basins. Furthermore, these are important attributes of oceanic Pn waves that can be used to assign magnitude for small- to moderate-size earthquakes in the equatorial mid-Atlantic region. The estimated station corrections correlate well with upper mantle low-velocity anomalies, especially in Brazil.

58 GEOSCIENCES↗
DOE OSTI2025

Effect of Zr and Sc additions on coarsening- and creep resistance of AlSi10Mg fabricated by laser powder bed fusion

Microstructure and creep properties are studied in a eutectic AlSi10Mg alloy modified with Zr and Sc additions (Al-9.8Si-0.32Mg-0.70Zr-0.23Sc, wt%) manufactured through laser powder-bed fusion (L-PBF). Three types of Zr/Sc-bearing powders - elemental, master-alloy, and pre-alloyed - are employed in the fabrication process, with the pre-alloyed powders providing the highest incorporation of Zr and Sc in the Al matrix. Here, the as-printed alloy exhibits a fine cellular Al-Si eutectic structure which fragments and coarsens into micron-sized Si particles during aging at 300 ºC, leading to a steady drop in alloy microhardness between 0.1 and 1000 h. Coarsening of the eutectic Si phase during aging is not measurably affected by Zr and Sc in solid solution, which precipitate during aging and increases strength, compensating weakening from Si coarsening between 1 and 200 h at 300 ºC. Atom-probe analysis in the peak-aged condition (96 h/300 °C) confirms the presence of Al 3 (Sc,Zr) secondary nano-precipitates with an average radius of 1.0 nm and some Si solubility. Micron-sized grains are present throughout the alloy, with ultra-fine-grained regions at the melt pool boundaries, neither of which coarsen during long-term aging at 300 ºC. Under creep conditions at 300 °C, the Zr/Sc-bearing alloy with Al 3 (Sc,Zr) nano-precipitates exhibits power-law behavior, with a high apparent stress exponent (n a = 9) and a high threshold stress (σ th = 43 MPa), exhibiting nearly double the strength of a Zr/Sc-free AlSi10Mg control alloy (σ th = 22 MPa).

36 MATERIALS SCIENCE↗