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At least 1,099 records · Page 61
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Characterization of multi-material 316L-Hastelloy X fabricated via laser powder-bed fusion

The aim of this work is to provide firsthand knowledge of 316 L stainless steel (316 L) and Hastelloy X (HX) multi-material processing via laser powder bed fusion (PBF). Specifically, microstructure of the interface is studied using scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), and X-ray diffraction (XRD). Surface metrology is performed to characterize the resulting surface roughness at the interface followed by tensile and flexural testing of multi-material samples to characterize the mechanical properties of the interfaces. Results showed that use of proper process parameters for each individual material led to formation of a compositional gradient at the interface that stretched for 240 μm (10–12 layers) with no evidence of cracking or porosity. The interface exhibited higher surface roughness compared to 316 L or HX as measured by arithmetic mean height, Sa, and maximum valley depth, Sv, parameters. During tensile testing, samples failed in the 316 L region away from the interface, with comparable yield strength, ultimate strength, and ductility. Finally, it was concluded that the “naturally” formed interface created a compositional gradient which was defect free due to similar values of coefficient of thermal expansion, input energy density, and different Marangoni numbers of the materials.

316L stainless Steel↗
DOE OSTI2022

Texture evolution during processing and post-processing of maraging steel fabricated by laser powder bed fusion

Abstract In this study, the evolution of solidification texture during LPBF of Ti-free grade 300 maraging steel, and its effect on texture development during subsequent post-fabrication heat treatments was characterized using Electron Backscatter Diffraction (EBSD). It was found that in the as-fabricated state, no texture was observed in the room temperature martensitic phase. However, the reconstructed parent austenite phase displayed a Cube texture with a minor fraction of Rotated Goss texture. During subsequent aging treatments involving two different routes, namely direct aging of the as-fabricated samples, and conventional solution treatment + aging of the as-fabricated samples, significant changes in the texture components of parent austenite were observed, whereas no changes in texture were observed in the room temperature martensitic phase. During direct aging, it was found that with an increase in the aging temperature up to 520 °C, the texture components of the parent austenite changed from Cube/Rotated Goss to Brass, whereas during the conventional solution treatment and aging cycle, interestingly a change in texture component to rotated copper was observed. The transitions in texture components have been discussed using the concepts of recrystallization and twinning in austenite during annealing and/or aging, and strain energy release maximization (SERM) theory. Furthermore, the importance of these preferred orientations on the mechanical properties was quantified using transformation potential diagrams.

36 MATERIALS SCIENCE↗
NASA NTRS1987

Comparison of the tribological properties of fluorinated cokes and graphites

The friction, wear, endurance life, and surface morphology of rubbed (burnished) fluorinated graphite and fluorinated coke materials were studied. Two different coke powders, a graphitic carbon powder, and a graphite powder were fluorinated and then tribologically investigated. In addition, one of the coke powders was reduced in size before fluorinating to evaluate the effect of a finer particle size on the tribological properties. For comparison, graphite and coke powders which were not fluorinated were also tribologically evaluated. Elemental analysis by emission spectroscopy was performed on each sample to determine the impurity content and X-ray diffraction analysis was performed to determine the crystallinity. Coke was found to have very little lubricating ability, but fluorinated coke did possess good lubricating properties. However, the fluorinated graphite and fluorinated graphitic carbon (which gave equivalent results) gave superior results to those obtained with the fluorinated cokes. No tribological benefit was found for using small versus a larger particle size of coke, at least when evaluated as a rubbed film.

Fusaro, Robert L.↗
NASA NTRS1988

Advantages of barium peroxide in the powder synthesis of perovskite superconductors

This paper compares reaction chemistry, material processing, and material characteristics for the solid state reaction using BaCO3 or BaO2 in the synthesis of perovskite superconductors. Results are presented for weight loss and X-ray diffraction, sample morphology and homogeneity as monitored by SEM and EDS, and the superconductivity critical temperature and ac susceptibility. Greater mass density, increased sample homogeneity, lower resistance, and improved reproducibility for material are found when BaO32 is used.

Hepp, A. F.↗
NASA NTRS1988

Comparison of the tribological properties of fluorinated cokes and graphites

The friction, wear, endurance life, and surface morphology of rubbed (burnished) fluorinated graphite and fluorinated coke materials were studied. Two different coke powders, a graphitic carbon powder, and a graphite powder were fluorinated and then tribologically investigated. In addition, one of the coke powders was reduced in size before fluorinating to evaluate the effect of a finer particle size on the tribological properties. For comparison, graphite and coke powders which were not fluorinated were also tribologically evaluated. Elemental analysis by emission spectroscopy was performed on each sample to determine the impurity content and X-ray diffraction analysis was performed to determine the crystallinity. Coke was found to have very little lubricating ability, but fluorinated coke did possess good lubricating properties. However, the fluorinated graphite and fluorinated graphitic carbon (which gave equivalent results) gave superior results to those obtained with the fluorinated cokes. No tribological benefit was found for using small versus a larger particle size of coke, at least when evaluated as a rubbed film.

Fusaro, Robert L.↗
DOE OSTI2020

Thermal Analysis of High Entropy Rare Earth Oxides

Phase transformations in multicomponent rare earth sesquioxides were studied by splat quenching from the melt, high temperature differential thermal analysis and synchrotron X-ray diffraction on laser-heated samples. Three compositions were prepared by the solution combustion method: (La,Sm,Dy,Er,RE) 2 O 3 , where all oxides are in equimolar ratios and RE is Nd or Gd or Y. After annealing at 800 °C, all powders contained mainly a phase of C-type bixbyite structure. After laser melting, all samples were quenched in a single-phase monoclinic B-type structure. Thermal analysis indicated three reversible phase transitions in the range 1900–2400 °C, assigned as transformations into A, H, and X rare earth sesquioxides structure types. Unit cell volumes and volume changes on C-B, B-A, and H-X transformations were measured by X-ray diffraction and consistent with the trend in pure rare earth sesquioxides. The formation of single-phase solid solutions was predicted by Calphad calculations. The melting point was determined for the (La,Sm,Dy,Er,Nd) 2 O 3 sample as 2456 ± 12 °C, which is higher than for any of constituent oxides. An increase in melting temperature is probably related to nonideal mixing in the solid and/or the melt and prompts future investigation of the liquidus surface in Sm 2 O 3 -Dy 2 O 3 , Sm 2 O 3 -Er 2 O 3 , and Dy 2 O 3 -Er 2 O 3 systems.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Post-build stress-relief optimization for laser powder bed fusion 316H stainless steel

Nuclear energy remains a critical component of a diversified and efficient energy portfolio, offering reliable, high-capacity, and low-carbon power. However, in the U.S., aging infrastructure and the slow qualification and deployment of advanced materials and manufacturing techniques hinder progress in next-generation reactor technologies. This study explores the application of laser powder bed fusion (LPBF) additive manufacturing for stainless steel 316H, with a focus on optimizing post-build heat treatments to enhance material properties for high-temperature nuclear applications. The research targets the optimization of stress-relief temperatures to alleviate postbuild residual stresses, ensuring improvements in the microstructural corelated properties. A series of microstructural and mechanical evaluations were performed on LPBF-printed SS-316H samples which were subjected to annealing at temperatures varying between 650 °C and 850 °C. X-ray diffraction, scanning electron microscopy, and transmission electron microscopy analyses revealed that increasing the heattreatment temperature accelerated dislocation recovery. Vickers microhardness measurements showed an initial reduction in values, followed by stabilization over extended durations at all the temperatures. While higher temperatures facilitated faster recovery, they also promoted carbide precipitation along grain and solidification cell boundaries, narrowing the safe processing window. In contrast, heat treatment at 650°C preserved the cellular substructure and enabled controlled carbide precipitation over time. In conclusion, these findings highlight the importance of time–temperature optimization and suggest that 650°C for up to 2 h provides the most favorable balance between recovery and carbide control for a stress-relief treatment.

316 stainless steel↗
DOE OSTI2026

Texture development in magnetostrictive Fe-Ga alloys processed by laser powder bed fusion

Iron-gallium (Fe-Ga, Galfenol) alloys are promising magnetostrictive materials for actuators, sensors, and energy harvesting, but their performance is highly sensitive to microstructure and texture. Additive manufacturing by laser powder bed fusion (LPBF) offers a pathway to engineer texture and integrate functional materials into complex geometries. Here, we fabricate Fe-Ga alloys (Fe 82.2 Ga 17.8 ) by LPBF of gas-atomized powders and systematically optimize laser power and scan speed to maximize density and control texture. Nearly full-density parts (up to 99.6 %) are achieved within a narrow processing window. Electron backscatter diffraction (EBSD) reveals a strong <100> fiber texture aligned with the build direction and columnar grains up to 1 mm long. Magnetostriction measurements show saturation magnetostriction of 190 ppm in the build direction. Correlating texture data with macroscopic magnetostriction, we estimate intrinsic magnetostriction constants (λ 100 = 228 ppm, λ 111 = 12 ppm), closely matching single crystal-derived values. These results demonstrate the critical interplay between processing, texture, and functional performance in additively manufactured Fe-Ga alloys and establish LPBF as a viable route for high-performance magnetostrictive materials.

Additive manufacturing↗
DOE OSTI2020

Effect of Liquid Electrolyte Soaking on the Interfacial Resistance of Li 7 La 3 Zr 2 O 1 2 for All-Solid-State Lithium Batteries

In this work, the impact of liquid electrolyte soaking on the interfacial resistance between the garnet-structured Li 7 La 3 Zr 2 O 12 (LLZO) solid electrolyte and metallic lithium has been studied. Lithium carbonate (Li 2 CO 3 ) formed by inadvertent exposure of LLZO to ambient conditions is generally known to increase interfacial impedance and decrease lithium wettability. Soaking LLZO powders and pellets in the electrolyte containing lithium tetrafluoroborate (LiBF 4 ) shows a significantly reduced interfacial resistance and improved contact between lithium and LLZO. Raman spectroscopy, X-ray diffraction, and soft X-ray absorption spectroscopy reveal how Li 2 CO 3 is continuously removed with increasing soaking time. On-line mass spectrometry and free energy calculations show how LiBF 4 reacts with surface carbonate to form carbon dioxide. Using a very simple and scalable process that does not involve heat-treatment and expensive coating techniques, we show that the Li–LLZO interfacial resistance can be reduced by an order of magnitude.

25 ENERGY STORAGE↗
DOE OSTI2022

The structure of sc16 GaP obtained at 17.5 GPa and 1400 K

We report using a laser-heated diamond anvil cell, a powdered sample of gallium phosphide was compressed to 17.5 GPa and heated up to 1400 K. The material obtained was characterized at room temperature using synchrotron x-ray diffraction. Experimental results were compared with first-principles calculations. The polymorph observed assumes the simple cubic structure (sc16) initially reported for GaAs at high pressures. Microdiffraction mapping showed variable grain sizes of the synthesized phase, with the largest grains located in the middle of the heated spot. Structural refinements were performed on selected grains. The structure predicted based on first-principles calculations is in close agreement with the experiments. The two Ga–P bonds show similar lengths in sc16-GaP; however, the bond angles differ, resulting in a distorted tetrahedral coordination geometry.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
NASA NTRS1990

Processing Bi-Pb-Sr-Ca-Cu-O superconductors from amorphous state

Researchers produced superconducting ceramics of the Bi-Pb-Sr-Ca-Cu-O system started from a glass. To form the glass, the mixed oxide powder was melted at 1200 C in air. The liquid was quenched rapidly by pouring it onto an aluminum plate and rapidly pressing with another plate. The quenched compound was in the form of black amorphous solid, whose x-ray powder pattern has no crystalline peaks. After heat treatment at high temperatures, the glass crystallized into a superconductor. The crystalline phases in the superconductor identified using x-ray diffraction patterns. These phases were that associated with the superconducting phases of T(sub c) = 80 K (Bi2Ca1Sr2Cu2Ox) and of T(sub c) = 110 K (Bi2Ca2Sr2Cu3Ox). The dc resistivity and the ac susceptibility of these superconductors were studied.

Chiang, C. K.↗
NASA NTRSDate not supplied

Tribological performance of Al2O3-B2O3 composites: Role of CuOand CaO constituents

Al2O3-B2O3 based composites for wear resistant applications (e.g., seal rings and bearings) were manufactured using powder metallurgy route. Four different compositions were considered to control amount of in situ phases, mainly aluminum borate, formed during sintering. The fabricated composites were characterized using X-ray diffraction to identify the phases. Hardness was measured in terms of micro-hardness. The tribological performance of the composites were evaluated by conducting dry sliding tests against alumina balls at different humidity levels (10 – 95% relative humidity). The X-ray spectrum revealed that increase in B2O3 content in the composites increased the amount of aluminum borate phase that enhanced the micro-hardness. Results revealed that aluminum borate enhanced the wear resistance of the composites, whereas the humidity-sensitive alumina phase reduced friction at higher humidity levels. Furthermore, CuO and CaO (2-5 wt.%) were added separately to the composite, resulting in increased density by 22-48 %. Athough the addition of CuO and CaO led to increase in hardness and wear resistance of the composites, the coefficient of friction was negatively affected. The friction and wear performance along with wear mechanism are discussed with respect to observed phases in the composites.

Ashish K. Kasar↗
DOE OSTI2021

Additive manufacturing of cobalt-based alloy on tool steel by directed energy deposition

Cladding hard-surfacing alloys on tool steel is an effective approach to enhance the surface properties of tool steel. In this study, a Co-based alloy was deposited on tool steel by Directed Energy Deposition (DED) following a three-factor three-level design of experiment matrix with varied laser power, scan speed, and powder flow rate. The microstructure of the deposits was characterized using scanning electron microscopy (SEM). The residual stress on the surface of the samples was measured by the X-ray diffraction (XRD) sin2? technique. The parameters that produced promising deposits were used to fabricate samples for tensile test, four-point bending test, Charpy impact test, and hardness measurement. Our result reveals that the processing parameters have a significant role in the residual stress of the coatings. Residual stress reduces with the increase of laser energy density. Cracks were found at samples with energy density below a threshold. Tensile testing of the coating/substrate combined structure reveals fracture at the coatings with an ultimate tensile strength of 633.9 ± 54.7 MPa. The bi-material interface survived the tensile test, indicating a strong interfacial bond. The four-point bending test of coating/substrate laminates shows an ultimate flexure strength of 860.6 ± 36.9 MPa. Cracks initiated from the coatings ignored the interface and penetrated the substrate, suggesting a solid bi-material bond. Charpy impact test shows the absorbed energy of coating/substrate laminates is more than doubled that of the substrate.

36 MATERIALS SCIENCE↗
DOE OSTI2023

A High-Speed Rotational Diamond Anvil Cell for In Situ Analysis of Hierarchical Microstructural Evolution of Metallic Alloys during Extreme Shear Deformation

High speed shear deformation is ubiquitous in engineering applications, ranging from material processing methods such as friction stir processing/extrusion and in tribological contacts. However, analyzing the microstructural evolution of materials while they are undergoing high speed shear deformation have been a long-standing challenge. This led to predominant reliance on ex situ microscopy before and after shear deformation. But ex situ microscopy lacks the ability to analyze dynamic and transient hierarchical microstructural evolution mechanisms that could occur during shear deformation of materials. Therefore, to better understand the dynamic mechanisms of mass and energy transfer in materials under shear deformation, we developed a first of its kind high-speed rotational diamond anvil cell (HS-RDAC) for synchrotron-based in situ high-energy x-ray diffraction (XRD). We studied the time resolved lattice strain evolution, XRD peak broadening and changes in spatial variation of shear deformation induced alloying in pure metal and metal alloy sheets and powder mixture using the HS-RDAC. These in situ results were combined with detailed ex situ microstructural characterization before and after the shear deformation using transmission electron microscopy and atom probe tomography, which revealed the different stages of evolution of a shear deformation induced hierarchical nanostructure. Multiscale computational simulations including computational fluid dynamics, crystal plasticity, molecular dynamic simulation and density functional theory uncovered the mechanisms behind morphological changes, evolution of defect structures and changes in driving force for shear deformation induced intermixing. In conclusion, this in situ HS-RDAC capability, in combination with ex situ microstructural characterization and computational simulations, can provide new insights into the hierarchical microstructural evolution pathway during shear deformation.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Computational and Experimental Characterization of Intermediate Amorphous Phases in Geological Materials

In the subsurface, MgO engineered barriers are employed at the Waste Isolation Pilot Plant (WIPP), a transuranic waste repository near Carlsbad, NM. During service, the MgO will be exposed to high concentration brine environments and may form stable intermediate phases that can alter the barriers effectiveness. Here, MgO was aged in water and three different brine solutions. X-ray diffraction (XRD) and 1 H nuclear magnetic resonance (NMR) analysis were performed to identify the formation of secondary phases. After aging, ~4% of the MgO was hydrated and fine-grained powders resulted in greater loss of crystallinity than hard granular grains. 1 H magic angle spinning (MAS) NMR spectra resolved minor phases not visible in XRD, indicating that diverse 1 H environments are present along with Mg(OH) 2 . Density functional theory (DFT) simulations for several proposed Mg-O-H, Mg-CI-O-H, and Na-O-H containing phases were performed to index peaks in the experimental 1 H MAS NMR spectra. While proposed intermediate crystal structures exhibited overlapping 1 H NMR peaks, Mg-O-H intermediates were attributed to the growth of the 1.0-0.0ppm peak while the Mg-CI-O-H structures contributed to the 2.5- 5.0ppm peak in the chloride containing brines. Overall, NMR analysis of aged MgO indicates the formation of a range of possible intermediate structures that cannot be resolved with XRD analysis alone.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2022

ADDITIVE MANUFACTURING OF REFRACTORY ALLOYS

Refractory alloys are known for their high temperature capabilities and are intended for use at ultra-high temperatures above even 1200°C, which exceeds the capabilities of conventional superalloys. Additive manufacturing (AM) is an attractive alternative processing route because refractory alloys are difficult to fabricate through traditional methods; AM can form a near net-shape part with a tailored microstructure. This work seeks to evaluate the solidification behavior of refractory alloys under AM conditions and establish corresponding solidification models. Two binary alloys, Mo30Nb and Nb7.5Ta, as well as the commercial Nb alloy, C103, and one refractory high entropy alloy (RHEA), MoNbTaTi, were subjected to single track melts in a laser powder bed fusion (LPBF) machine. Each melt track was evaluated in the scanning electron microscope (SEM), which determined that some AM conditions used led to non-ideal behavior. Electron backscatter diffraction (EBSD) revealed that the Nb7.5Ta, C103, and MoNbTaTi all exhibited new grain nucleation to various extents while the Mo30Nb exhibited primarily epitaxial growth. This was found to be inconsistent with solidification models that were developed for each alloy and each set of AM conditions to predict the columnar to equiaxed transition behavior (CET) of the experimental microstructures. This disparity was largely attributed to the input parameters for the solidification model, which were developed using Thermo-Calc and SYSWELD. These input parameters include the alloy specific Gibbs-Thomson coefficient and thermophysical properties, the solute specific liquidus slopes and partitioning coefficients, as well as the process specific thermal gradients. Each input parameter was evaluated to determine the likely changes required for the modeled values to generate solidification models that better correspond to what was observed experimentally.

Miklas, Abigail↗
NASA NTRS1994

The oxidation state of the surface of Venus

We present experimental results showing that basalt is oxidized in CO-CO2 gas mixtures having CO number densities close to those (approximately 2 times higher) at the surface of Venus. The results suggest that the red color observed by Pieters et al at the Venera 9 and 10 landing sites is due to subaerial oxidation of Fe(2+)-bearing basalt on the surface of Venus, and that hematite, instead of magnetite, is present on the surface of Venus. Well-characterized basalt powder was iosthermally heated in 1000 ppm CO-CO2 gas mixtures at atmospheric pressure for several days. The starting material and reacted samples were analyzed by Mossbauer spectroscopy to determine the amount of Fe(2+) and Fe(3+) in the samples. X-ray diffraction and optical microscopy were also used to characterize samples. The basalt oxidation occurs because the CO and CO2 do not equilibrate in the gas mixture at the low temperatures used. Thus, the basalt reacts with the more abundant CO2 and is oxidized. We propose that the red color of the surface of Venus is due to failure of CO and CO2 to equilibrate with one another in the near-surface atmosphere of Venus, leading to subaerial oxidation of erupted Fe(2+)-bearing basalts. Our interpretation is supported by our studies of magnetite oxidation, which show that synthetic magnetite powders are oxidized to hematite in CO-CO2 gas mixtures inside the magnetite stability field, by our studies of pyrite decomposition, and by independent work on CO-CO2 equilibration in furnace gases.

Fegley, B., Jr.↗
DOE OSTI2020

Scattering Signatures of Bond-Dependent Magnetic Interactions

Bond-dependent magnetic interactions can generate exotic phases such as Kitaev spin-liquid states. Experimentally determining the values of bond-dependent interactions is a challenging but crucial problem. In this paper, I show that each symmetry-allowed nearest-neighbor interaction on triangular and honeycomb lattices has a distinct signature in paramagnetic neutron-diffraction data, and that such data contain sufficient information to determine the spin Hamiltonian unambiguously via unconstrained fits. Moreover, I show that bond-dependent interactions can often be extracted from powder-averaged data. These results facilitate experimental determination of spin Hamiltonians for materials that do not show conventional magnetic ordering.

36 MATERIALS SCIENCE↗