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At least 1,081 records · Page 60
All sourcesNASA NTRSDOE OSTI
DOE OSTI2017

Experimentally Determined Phase Diagram for the Barium Sulfide-Copper(I) Sulfide System Above 873 K (600 °C)

The phase diagram of the barium sulfide-copper(I) sulfide system was investigated above 873 K (600 °C) using a custom-built differential thermal analysis (DTA) apparatus. The melting point of barium sulfide was determined utilizing a floating zone furnace. Four new compounds, Ba{sub 2}Cu{sub 14}S{sub 9}, Ba{sub 2}Cu{sub 2}S{sub 3}, Ba{sub 5}Cu{sub 4}S{sub 7}, and Ba{sub 9}Cu{sub 2}S{sub 10}, were identified through quench experiments analyzed with wavelength dispersive X-ray spectroscopy (WDS) and energy dispersive X-ray analysis (EDS). A miscibility gap was observed between 72 and 92 mol pct BaS using both DTA experiments and in situ melts observation in a floating zone furnace. A monotectic was observed at 94.5 mol pct BaS and 1288 K (1015 °C).

36 MATERIALS SCIENCE↗
DOE OSTI2017

Advanced Process Possibilities in Friction Crush Welding of Aluminum, Steel, and Copper by Using an Additional Wire

Joining sheet metal can be problematic using traditional friction welding techniques. Friction crush welding (FCW) offers a high speed process which requires a simple edge preparation and can be applied to out-of-plane geometries. In this work, an implementation of FCW was employed using an additional wire to weld sheets of EN AW5754 H22, DC01, and Cu-DHP. The joint is formed by bringing together two sheet metal parts, introducing a wire into the weld zone and employing a rotating disk which is subject to an external force. The requirements of the welding preparation and the fundamental process variables are shown. Thermal measurements were taken which give evidence about the maximum temperature in the welding center and the temperature in the periphery of the sheet metals being joined. The high welding speed along with a relatively low heat input results in a minimal distortion of the sheet metal and marginal metallurgical changes in the parent material. In the steel specimens, this FCW implementation produces a fine grain microstructure, enhancing mechanical properties in the region of the weld. Aluminum and copper produced mean bond strengths of 77 and 69 pct to that of the parent material, respectively, whilst the steel demonstrated a strength of 98 pct. Using a wire offers the opportunity to use a higher-alloyed additional material and to precisely adjust the additional material volume appropriate for a given material alignment and thickness.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Evolution of Size and Chemical Composition of Copper Concentrate Particles Oxidized Under Simulated Flash Smelting Conditions

An experimental study was conducted to elucidate the evolution of size and chemical composition of La Caridad copper concentrate particles during oxidation under simulated flash smelting conditions. Input variables tested included particle size and oxygen concentration in the process gas. The response variables included the size distributions, chemical composition, and morphology of the reacted particles at seven locations along a laboratory reactor. Particles with initial size < 45 µm contained mostly chalcopyrite, they increased their mean size and decreased the amount of dust in the population during oxidation. This was explained by a reaction path involving rapid melting followed by collision and coalescence of reacting droplets during flight. Particles with sizes > 45 µm contained varying amounts of chalcopyrite and pyrite, and tended to either maintain or decrease their mean size upon oxidation. When size reduction was observed, dust was produced because of fragmentation, and the particles showed no evidence of collisions during flight. The main oxidation products detected in the particles consisted of matte, cuprospinel, and magnetite. A plot of the mean size divided by the mean size in the feed against the fraction of sulfur eliminated generalized the experimental data so far reported in the literature, and helped identify the reaction path followed by the particles.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Exploring As-Cast PbCaSn-Mg Anodes for Improved Performance in Copper Electrowinning

Lead calcium tin (PbCaSn) alloys are the common anodes used in copper electrowinning (Cu EW). Given a large amount of energy consumed in Cu EW process, anodes with controlled oxygen evolution reaction (OER) kinetics and a lower OER overpotential are advantageous for reducing the energy consumption. To date, magnesium (Mg) has never been studied as an alloying element for EW anodes. As-cast PbCaSn anodes with the addition of Mg were examined herein, revealing an improved performance compared to that of the industrial standard PbCaSn anode. The alloy performances in the early stages of anode life and passivation were established from electrochemical studies which were designed to simulate industrial Cu EW process. The 24-hour polarization testing revealed that the Mg alloying depolarizes the anode potential up to 80 mV; thus, resulting in a higher Cu EW efficiency. In addition, scanning electron microscopy and X-ray photoelectron spectroscopy revealed that the alteration of the alloy microstructure and the corresponding interfacial reactions contribute to the changes of the anode electrochemical performances. The present study reveals for the first time the potency of Mg alloying in reducing the overpotential of PbCaSn anode.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Compositional and Thermal Characterization of Potential Nano-Carbon Copper Composite

Covetic materials have been claimed to be new types of metal matrix nano-composite materials. These materials are formed from face-centered-cubic metals which are alleged to be super-saturated with up to ~ 10 wt pct of activated nano-carbon. The focus of this study was to characterize the chemical composition of copper covetic materials of varying nano-carbon concentrations, and characterize the thermal properties of these materials in order to determine if these materials exhibit enhanced material properties.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Study of the Influence of Xanthate Derivative Structures on Copper Sulfide Mineral Adsorption Under Acidic Conditions

Adsorption of commercial xanthate derivatives on copper sulfide mineral (covellite, CuS) was studied by kinetics and isotherm adsorption experiments. The adsorption of xanthate derivatives was confirmed by FTIR (Fourier transform infrared spectroscopy) and XPS (X-ray photoelectron spectroscopy) results. Experiments were performed with two different xanthate derivatives, C-4410 (O-pentyl S-2-propenyl ester) and C-4940 (isobutyl xanthogen ethyl formate), on individual doses of 0.05 g of powdered covellite. It was found that the equilibrium times at pH 2, 4, and 6 were different for both xanthate derivatives. The shortest times were achieved at pH 2 and 4. The results suggest that C-4110 can be used as collector in a wide range of pH, while C-4940 is limited to lower pH values. Pseudo first- and pseudo second-order kinetics models were thus applied to the experimental data for pH 2. The information obtained from the kinetics models combined with XPS allowed proposing the adsorption mechanism for the covellite-xanthate derivative pair. The adsorption takes place through a non-covalent interaction for C-4410 and chemisorption process for C-4940. The best-fitting isotherm models for C-4410 and C-4940 adsorption were Redlich–Peterson and Freundlich, respectively, which yield a maximum adsorption capacity of 57.07 mg g{sup −1} for C-4410 and 44.62 mg g{sup −1} for C-4940.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Accelerated Oxygen Mass Transfer in Copper and Vanadium Oxide-Based MIEC-Redox Membrane

Mixed ionic-electronic conducting (MIEC) membranes have a great potential for use in gas separation technology in the production of pure oxygen for metallurgy, micro- and nanoelectronics, biotechnology, pharmaceutics, etc. Before this happens, an important issue has to be addressed. This issue involves the design of novel MIEC membranes with enhanced oxygen transport. Recently, a concept of thick two-layer solid/liquid composite MIEC-Redox membranes with accelerated diffusion-bubbling oxygen transfer was proposed (see Belousov and Fedorov in ACS Appl Mater Interfaces 10:21794–21798, 2018). These diffusion-bubbling membranes could serve for efficient oxygen separation from air. However, there is no enough fundamental understanding of the mass transport processes involved. This understanding is important for evaluating the potential of MIEC-Redox membranes for practical application. The presented article gives a theory of oxygen mass transfer in two-layer copper and vanadium oxide-based MIEC-Redox membranes. The theory describes both the transport of oxygen ions in the outer layer of the membrane and the nucleation, growth, and transport of oxygen gas bubbles in the inner layer of the membrane. Kinetic regularities of oxygen mass transfer are established. The ways to enhance the productivity of MIEC-Redox membranes are outlined.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Microstructure Evolution and Failure Analysis of an Aluminum–Copper Cathode Conductive Head Produced by Explosive Welding

In this paper, microstructure evolution and failure analysis of the aluminum-copper interface of cathode conductive heads during their use were studied. The interface morphologies, compositions, conductivity and mechanical properties were investigated and analyzed. Obvious corrosion was found on the surface of the contact interface, which was more prevalent on an Al matrix. The crack increased sharply in the local metallurgical bonding areas on the interface, with the compound volume having no significant change. The phase transformation occurred on the interface during use, which was investigated using the elemental composition and x-ray diffraction pattern. The microhardness near the interface increased accordingly. An obvious electrical conductivity decrease appeared on the Al/Cu interface of the cathode conductive head after use over a specific time interval. Therefore, the deterioration of the microstructures and corrosion are the primary factors that affect the electrical conductivity and effective bonding, which will lead to eventual failure.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Fiber Laser Welding–Brazing Characteristics of Dissimilar Metals AZ31B Mg Alloys to Copper with Mg-Based Filler

Fiber laser welding–brazing of 1-mm-thick AZ31B Mg alloys to 1.5-mm-thick copper (T2) with Mg-based filler was performed in a lap configuration. The weld appearance, interfacial microstructure and mechanical properties were investigated with different heat inputs. The results indicated that processing windows for optimizing appropriate welding parameters were relatively narrow in this case. Visually acceptable joints with certain strength were achieved at appropriate welding parameters. The maximum tensile-shear fracture load of laser-welded-brazed Mg/Cu joint could reach 1730 N at the laser power of 1200 W, representing 64.1% joint efficiency relative to AZ31Mg base metal. The eutectic structure (α-Mg + Mg{sub 2}Cu) and Mg-Cu intermetallic compound was observed at the Mg/Cu interface, and Mg-Al-Cu ternary intermetallic compound were identified between intermetallics and eutectic structure at high heat input. All the joints fractured at the Mg-Cu interface. However, the fracture mode was found to differ. For laser power of 1200 W, the surface was characterized by tearing edge, while that with poor joint strength was almost dominated by smooth surface or flat tear pattern.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Design and Performance Evaluation of Al{sub 2}O{sub 3}-SiC Composite for Direct-Bonded Copper Substrate

A computational material design approach is applied to propose a novel ceramic material for direct-bonded copper (DBC) substrate with enhanced thermal and structural performance. The material design inherently consists of many competing requirements that require careful decisions regarding key trade-offs in terms of material composition, inclusion size, shape, and distribution to achieve the target properties. The alumina-silicon (Al{sub 2}O{sub 3}-SiC) composite, as compared to commercial alumina, used in DBC is found to be the most suitable design among other candidates with improved thermal and structural properties. In order to study the performance characteristics and the effects of the new ceramic composite with improved properties in terms of structural behavior and fatigue life of the DBC substrate, the normal working and extreme thermal cycling conditions were simulated and analyzed using finite element method. The temperature, strain, and localized stress distribution within the substrate at a steady-state condition were analyzed, and the improved Coffin–Manson law was used to calculate the fatigue life of the substrate under extreme thermal cycling conditions. The proposed Al{sub 2}O{sub 3}-SiC composite is found to be more robust than the commercial alumina as DBC substrates considering the thermal–mechanical performance. The fatigue life cycle of the DBC substrate with the proposed material is predicted to be about two times longer than the commercial alumina DBC ceramic under transient thermal cycling test.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Investigation of Current Parameters and Size Effects on Mechanical Properties During Pulsed Electrically Assisted Uniaxial Tension in T2 Red Copper Sheets

It has been found that the electrically assisted (EA) forming can alleviate size effects due to the electroplastic effect. Size effects exist in the manufacture of tiny workpieces and severely affect material performances because the grain boundary hardening effect and strong anisotropy of the mechanical properties of the grains will lead to a strong variation in the forming properties of the sheet. In order to investigate the influences of current parameters and size effects on mechanical properties in EA forming, EA uniaxial tension tests with varying grain size and thickness were conducted on T2 red copper sheets. The small temperature rise shows the thermal effect is slight; the flow stress decreases with the increase in pulse frequency, pulse duty ratio and current density; the finer grains still result in higher strength and better plasticity; Moreover, the fluctuations of tensile strength, maximum uniform strain and fracture strain decrease with the increase in the ratio of thickness to grain size (N) at constant current density, which means pulsed current can weaken size effects.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Dynamic Frictional Characteristics of TP2 Copper Tubes during Hydroforming under Different Loading and Fluid Velocities

Tube hydroforming (THF) experiments were performed on TP2 copper tubes under different loading velocities and fluid velocities using a self-developed measurement system to investigate dynamic frictional characteristics in the guiding zone. The results show that the coefficient of friction (COF) dynamically changes during forming experiments and decreases with tube deformation. The average descending rate and amplitude of the COF increase with increasing loading velocity. Microscopically, the micro-protrusions on the tubular surface are flattened, and the surface scratches are finer and more uniform, as the loading velocity increases, resulting in a decrease in COF. At the same external loading velocity, the COF increases with increasing fluid velocity and is also extremely sensitive to it. Moreover, improving and predicting the formability of such tubes by accurately adjusting and controlling fluid velocity in THF is valuable and critical for the future.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effects of Transition Layer on Bending Resistance in Copper-Clad Aluminum Composite Casting

The performance of the transition layer in a Cu/Al composite casting directly affects the quality of subsequent plastic deformation processing; however, there are no universal or standardized measurement indices for the performance of the transition layer. In this study, Cu/Al composite castings were prepared using the pouring aluminum method, and the resulting solidification microstructures on the bending resistance were investigated. The results of this study lay a theoretical foundation for the development of the plastic processing technologies of these composite castings. A thinner transition layer in the Cu/Al composite casting led to improved bending resistance. In addition, for a fixed total thickness of the transition layer, the bending resistance was mainly controlled by the γ/β interface and β + eutectic (α + β) microstructure, and the thickness of the γ phase had a negligible effect on the bending resistance. The γ/β interface cracked first when the transition layer bore the tensile and shear stress during the bending process, which resulted in the transition layer easily separating from the copper. The bending resistance of the transition layer can be feasibly judged by measuring the bending angle of the specimen tip, which can be easily performed when the specimen bends toward the aluminum direction, suggesting that our proposed method has considerable practical significance.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Nickel-Coated Super-Aligned Carbon Nanotube Reinforced Copper Composite for Improved Strength and Conductivity

Nickel (Ni)-coated super-aligned carbon nanotube (SACNT) films-reinforced copper (Cu) matrix composites were fabricated by electrodeposition. The microstructure, mechanical property and electrical conductivity of the prepared composites have been studied systematically. The results show that the mechanical properties of SACNT/Cu were significantly improved by coating SACNT with Ni. When the volume fraction of SACNT is 10.0%, the tensile strength and yield strength of the composite can reach 477.8 and 295.5 MPa, respectively, corresponding to 147 and 170% improvement compared to pure Cu prepared by the same method. Meanwhile, due to the super-aligned arrangement of SACNTs and the homogeneous distribution of Ni, which is not mixing or dissolving with Cu, the conductivities of all the Ni-coated SACNT-reinforced Cu composites are above 58% IACS, which is about 4 times higher than the results in previous research. The enhancement of the strength of the SACNT/Cu composites comes from the combined contribution of load transfer and grain refinement strengthening.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Deformation Behavior of Pure Copper Castings with As-Cast Surfaces for Electrical Parts

Herein, the tensile deformation behavior of pure copper castings with as-cast surfaces was investigated. It was found that small and sufficiently large uniform elongation types corresponded, respectively, to the presence or absence of a Cu-Cu{sub 2}O eutectic phase in the microstructure. Fissure defects were observed near the as-cast surfaces when the eutectic phase was present, probably leading to stress concentration. On the other hand, surface pinholes were observed when the eutectic phase was absent, and these were not prevented by directional solidification. Although the as-cast specimens (non-directionally solidified) exhibited a slightly reduced uniform elongation compared to the machined specimens in the absence of the eutectic phase, the directionally solidified as-cast samples exhibited a uniform elongation that was similar to that of the machined specimens. In addition, micropore arrays were formed along the grain boundaries inside the castings when the eutectic phase was absent, whereas almost no micropores were observed inside the directionally solidified as-cast specimens because the solidification process involved a faster cooling rate and/or higher temperature gradient. These results do not only suggest the existence of surface pinholes but also indicate that microporosity can reduce the cross-sectional area of the specimens, thus, affecting their uniform elongation.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Correlations Between Spall Damage Mode Preference and Microstructure in Shocked Polycrystalline Copper: A 3-D X-Ray Tomography Study

Nondestructive characterization techniques are essential for maximizing the amount of high fidelity data obtained from post mortem mechanically tested materials, particularly for the complex experimental techniques used for shock loading. Polycrystalline copper samples of varying thermomechanical histories were shock loaded to induce incipient spall damage conditions via plate impacts at low pressures. Electron backscattering diffraction (EBSD) and 3-D X-ray tomography (XRT) were utilized to obtain microstructural and void volume data, respectively. Voids were fit to ellipsoids using their inertia tensors obtained from the 3-D XRT data, and the results compared to EBSD data. This, in turn, enabled establishing quantitative correlations between void shapes and preferential damage mode, either inter- or trans-granular, for each thermomechanical history. Greater than 60 % of voids present in heat-treated samples were spherical, indicative of transgranular damage preference. Greater than 90 % of voids present in as-received rolled samples were flat sheetlike voids or unsymmetrical oblate ellipsoids, indicative of intergranular and coalesced damage modes. Analyzing grain boundary damage statistics in conjunction with global damage mode distributions indicate that boundaries become less dominant as preferential void nucleation sites within the spall plane as the bulk strength of the material decreases from heat treatments.

Microstructure↗
DOE OSTI2015

Effect of ZrO 2 , Al 2 O 3 and La 2 O 3 on cobalt–copper catalysts for higher alcohols synthesis

In this work three cobalt–copper catalysts singly promoted with La, Zr, or Al were studied for catalytic conversion of syngas to higher alcohols. The properties of the promoted catalysts have been characterized by TPR, XRD, XPS and BET. CO hydrogenation was carried out in a plug-flow reactor under 30 bar, GHSV = 36000 scc/g cat /h, H 2 /CO = 2, and 250 °C at differential conversions. The catalyst activity and selectivity to higher alcohols are greatest on CuCoLa 2 O 3 :ethanol selectivity 10.5% at a conversion of 0.76%. During 9 h of time-on-stream, CO conversion decreased on CuCoLa 2 O 3 while methanol and higher alcohol selectivity increased. The behaviors on CuCoZrO 2 and CuCoAl 2 O 3 were different. On these two catalysts, CO conversion and selectivity reached a near-steady state much more quickly than CuCoLa 2 O 3 . These results suggest changes on CuCoLa 2 O 3 that increase the selectivity for oxygenates continue with time, at least over the time scale investigated here.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2019

Aerobic oxidative coupling of amines to imines by mesoporous copper aluminum mixed metal oxides via generation of Reactive Oxygen Species (ROS)

We report a mesoporous, monomodal copper aluminum mixed metal oxide (MMO) (average pore size 9.63 nm, surface area 140 m 2 /g) synthesized via a modified inverse micelle method, efficiently catalyzes aerobic oxidative coupling of amines to imines. This material exhibits excellent conversion (> 99%) and selectivity (> 99%) towards imine synthesis under mild, solvent free, green conditions utilizing atmospheric air as the sole oxidant. Catalytic activity is observed for a diverse range of amine substrates. The aerobic oxidation of amines to imines follows a unique mechanistic pathway which involves Reactive Oxygen Species (ROS).

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗