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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 1,153 records · Page 64
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Behavior of yttria-stabilized zirconia (YSZ) during laser direct energy deposition of an Inconel 625-YSZ cermet

Thermal barrier coatings (TBC) are regularly used today to protect and extend the service life of several superalloys which are extensively used in high temperature applications. The existing TBCs are typically between 0.1 to 0.5 mm in thickness, are deposited on metal substrates using plasma spray or electron beam vapor deposition, and can reduce temperatures at the substrate surface by up to 300 °C. For greater temperature reductions there is a need for thicker TBCs. The building of thick TBCs has to date been stymied by poor adhesion, and cracking during deposition. It has been suggested that a functionally graded approach may reduce the residual stresses which result in these defects. To date there have been few reports on the deposition of ceramic or cermet coatings using laser AM and none have reported on the phase stability of ceramic particles post-deposition. This article is a first report on the phase stability of ceramic particles following the compositional segregation of elements during deposition using a powder feed additive manufacturing process. Functionally graded (FG), thick TBCs (>3 mm) consisting of Inconel 625 (IN625) and yttria-partially stabilized zirconia (8YSZ) were deposited on an A516 steel substrate via laser direct energy deposition (LDED). Good interfaces were observed between the bond coat (BC) and first cermet layer and between the graded cermet layers. However, cermet layers deposited with 10 wt.% or more YSZ developed a thin layer of YSZ on the surface. The thin layer of YSZ greatly hindered additional deposition of new cermet layers. In cermet layers that did exhibit good interfaces, fine, re-solidified, YSZ particles were homogenously distributed within the Inconel 625 matrix. The YSZ particles exhibited a tetragonal lattice structure and were depleted of yttrium. In contrast, the thin YSZ layer formed on a cermet surface showed no yttrium depletion.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Thermal characterization of the build chamber in electron beam melting

Electron beam powder bed fusion, commonly termed electron beam melting (EBM), offers great versatility in multiple-part processes and can produce high quality as-built components due to low residual stresses. The EBM process is complex and requires careful thermal management, including uniform and consistent preheating of the powder bed, in order to ensure quality and consistency of the product. However, most of the simulations in the literature focus on the selective melting stage of the process. As of today, optimal conditions for initial pre-heating temperatures are only available for specific materials. Thus, in order to extend the EBM technology to other desired build materials, a much better understanding of the pre-heating stages is required. In this work, numerical and experimental approaches are combined in order to investigate the effects and sensitivities of heat removal from the build plate during EBM pre-heating stages. For this purpose, a carefully reconstructed numerical model of the build chamber of an ARCAM Q20 + machine is developed. It includes all main parts of the chamber and all relevant heat transfer mechanisms, whereas special attention is paid to radiation heat exchange between various bodies. In order to validate the model, dedicated experiments are performed, in which a system of thermocouples is installed in the build chamber, allowing direct measurement of the local temperatures of the start-plate and heat shields. A good agreement between the simulation and experimental findings is achieved, leading to a better understanding of the thermal processes characteristic to the pre-heating stages. This basic analysis is followed by a representative pre-heating case, where a powder bed is also considered. The energy required to obtain the desired pre-heating temperatures is evaluated, and the role of the powder bed in heat transfer within the chamber is assessed. The pre-heating stage, simulated in the present work, is supposed to create proper conditions for sintering and consequent melting of the powder, which are highly dependent on the local temperatures and heat transfer features. Thus, the findings of the reported work present a step towards a better understanding of the thermal processes that characterize EBM. The reported model can be further used to provide realistic boundary condition inputs for other meso- or macro-scale models as a function of time and geometry. The model can serve also for verification of machine settings, i.e., jump-safe and melt-safe ones which actually provide desired preheat, and for development of settings for new powders.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Review of Computer-Aided Manufacturing (CAM) strategies for hybrid directed energy deposition

Hybrid additive manufacturing intertwines both additive and subtractive manufacturing layer by layer to digitally fabricate parts with complex geometries, improved surface finish and tight dimensional accuracies, the sum of which is difficult to obtain with any single process. Computer-Aided Manufacturing (CAM) software is required to orchestrate the machine toolpathing for both the deposition as well as the machining processes and is crucial for the successful fabrication of high quality structures. Additionally, CAM requires substantial operator input to account for challenging aspects of each fabricated structure. For example, deciding at which layer of deposition will the machining process continue to maintain access to complex cavities for finishing - internal features that would otherwise be unfinishable due to reach limitations or obstructions. Moreover, of the many commercially-available hybrid systems, each has a unique kinematic environment which can benefit from specific optimization of toolpath planning and substantial research has directly correlated toolpathing with the microstructure evolution, mechanical properties, porosity and residual stress state of the final fabricated part. This review explores the available strategies for CAM in the context of hybrid direct energy deposition, discusses the advantages and disadvantages of each and considers future CAM trends for this transformational digital manufacturing technology.

36 MATERIALS SCIENCE↗
DOE OSTI2025

A detailed study of pre-heating effects in electron beam melting powder bed fusion process

Metal-based additive manufacturing processes, such as powder bed fusion with electron beam (PBF-EB) process, also referred to as electron beam melting (EBM), can produce high-density parts with minimal residual stresses due to the uniform and coherent preheating of the powder bed. However, understanding and controlling the multiple stages of preheating is required to enable the production of high-quality, consistent parts of various materials. This work presents a large-scale, multi-layer, three-dimensional numerical analysis focused on studying the preheating stages for predicting thermal history during the PBF-EB process. The model follows a continuous multi-stage cyclic process, that incorporates all the main stages of the PBF-EB process for 316 L stainless steel. This includes the gradual deposition of a new powder layer, the first and second preheating levels of the powder bed, and the energy deposition during melting (excluding the actual melt-pool behavior simulation). The model employs an adaptive time-scaling approach that automatically adjusts the energy deposition for each solution time-increment. This allows for localized changes in time-resolution over an otherwise computationally expensive multi-layer procedure. The material property variations are also taken into account, with an emphasis on the subtle irreversible changes in powder effective thermal conductivity after the two requisite preheating stages of the powder bed. This effect is studied using simplified conductivity models from the literature for partially sintered powder, validated by a dedicated experiment and numerical simulation. The large-scale model is then used to estimate the actual temperatures during first and second preheating levels for 316 L steel, which is not yet fully supported commercially for PBF-EB. Model predictions are corroborated by experiments, using and analyzing IR images, taken at the completion of each layer by the machine’s built-in infrared camera. The current model also incorporates a qualitative assessment for the effects of conductivity change during pre-heating, as well as evaluates the applicability of the time-scaling approach.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Improving stability of ALD ZrN thin film coatings over U-Mo dispersion fuel

Atomic layer deposition (ALD) of ZrN is a candidate technology for coating U-Mo dispersion fuel as a diffusion barrier coating. During the early development stages of the coating the ZrN deposition showed to be mechanically unstable and ultimately resulted in spalling. Based on experimental outcomes it was found that instabillity can be eliminated through the introduction of a thin amorphous (a) Al 2 O 3 interlayer coating deposited in between the ~1-μm thick ZrN and the U-Mo. substrate. To elucidate these findings simulations were performed with density functional theory (DFT) to measure work of adhesions at different interfaces while finite element modeling (FEM) was performed to measure the residual stress distribution. DFT indicated that the ZrN coating deposited over (a)-Al 2 O 3 is ~2.5 times stronger when compared to direct deposition over U or UO 2 substrate. While calculations from FEM recognized; (1) large stress concentrations can originate from the irregularly distributed native surface oxides (UO 2 ) over U-Mo and (2) stress concentrations can be reduced if those surface UO 2 can be modified to a uniform layer (achieved after application of a 8 nm (a)-Al 2 O 3 interlayer). These results provided explanations and confirmed the role played by interlayer in eliminating the original mechanical instability of the ZrN.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Helium tribology of Inconel 617 subjected to laser peening for high temperature nuclear reactor applications

Inconel 617 is among the best candidates for utilization in high temperature gas cooled reactor tribo-components. However, the combined effects of sliding contact, along with intermittent idle times and very high temperature material degradation, deteriorates the alloy tribological performance, especially under a helium atmosphere. Laser peening is a surface treatment technique which can enhance the properties at the surface and subsurface by generating deep residual stresses and enhanced microstructure. In this work, we report the tribological behavior of regular laser peened as well as thermally-engineered laser peened Inconel 617 under helium and air atmospheres at 800 °C. In addition to friction and wear studies, the specimens are characterized by different analytical techniques to further understand the mechanisms involved in the peening process and sliding contact. Regardless of the peening process and post-process treatment types, it is observed that laser peening improves the tribological characteristics of Inconel 617. Interestingly, laser peening followed by helium thermal aging shows highly enhanced tribological behavior. This is attributed to the strengthening effect of the laser peening on the surface oxides providing an excellent and lasting protective and lubricating film under helium exposure.

42 ENGINEERING↗
DOE OSTI2017

Effect of silicon and oxygen dopants on the stability of hydrogenated amorphous carbon under harsh environmental conditions

Harsh environments pose materials durability challenges across the automotive, aerospace, and manufacturing sectors, and beyond. While amorphous carbon materials have been used as coatings in many environmentally-demanding applications owing to their unique mechanical, electrical, and optical properties, their limited thermal stability and high reactivity in oxidizing environments have impeded their use in many technologies. Silicon- and oxygen-containing hydrogenated amorphous carbon (a-C:H:Si:O) films are promising for several applications because of their higher thermal stability and lower residual stress compared to hydrogenated amorphous carbon (a-C:H). However, an understanding of their superior thermo-oxidative stability compared to a-C:H is lacking, as it has been inhibited by the intrinsic challenge of characterizing an amorphous, multi-component material. Here, we show that introducing silicon and oxygen in a-C:H slightly enhances the thermal stability in vacuum, but tremendously increases the thermo-oxidative stability and the resistance to degradation upon exposure to the harsh conditions of low Earth orbit (LEO). The latter is demonstrated by having mounted samples of a-C:H:Si:O on the exterior of the International Space Station via the Materials International Space Station (MISSE) mission 7b. Exposing lightly-doped a-C:H:Si:O to elevated temperatures under aerobic conditions or to LEO causes carbon volatilization in the near-surface region, producing a silica surface layer that protects the underlying carbon from further removal. In conclusion, these findings provide a novel physically-based understanding of the superior stability of a-C:H:Si:O in harsh environments compared to a-C:H.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Machining-induced surface transformations of magnesium alloys to enhance corrosion resistance in human-like environment

We report that magnesium alloys are becoming increasingly attractive for producing temporary prosthetic devices thanks to their bioresorbable characteristics in human body. However, their poor corrosion resistance to body fluids seriously limits their applicability. In this work, machining-induced surface transformations are explored as means to enhance corrosion resistance of AZ31 magnesium alloy. Surface characteristics including topography, residual stresses, wettability, microstructures and depth of transformed layer, were analysed and correlated to in-vitro corrosion resistance. Results showed that cryogenic machining at low feed provided the most promising corrosion reduction. Finally, thorough physical characterizations gave fundamental insights into possible drivers for this enhanced resistance.

36 MATERIALS SCIENCE↗
DOE OSTI2024

A Gaussian Process-Based extended Goldak heat source model for finite element simulation of laser powder bed fusion additive manufacturing process

In this study, laser powder bed fusion (L-PBF) additive manufacturing (AM) is a key enabling technology to manufacture highly complex and integrated metallic structures. In L-PBF AM process, the melting of the metal powders and the layers underneath can be governed by either “conduction mode” or “keyhole mode”, with the keyhole mode reportedly leading to porosity and decreased strength and ductility by many studies. In part scale simulations, finite element (FE) model is often used to study the temperature distribution during printing and to predict the residual stress, where a volumetric heat flux with a Gaussian or a double ellipsoidal (Goldak) distribution is often applied as the laser heat source. However, the above heat source models can only capture the melt pool shape in the conduction mode, and fail to capture the transition to keyhole melting mode when the process parameters change. To overcome this inaccuracy, an extended Goldak heat source model is proposed by introducing a laser penetration term as a function of laser parameters obtained from a Gaussian-Process (GP) model. The model is validated by “2D pad” AlSi10Mg L-PBF experiments under a wide range of laser power, scan speed, and laser focus offset, and the results show the model successfully captures the measured melt pool shape in all conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Influence of surface modifications on pitting corrosion behavior of nickel-base alloy 718. Part 1: Effect of machine hammer peening

The effect of surface modifications induced by machine hammer peening on pitting corrosion behavior of nickel-base alloy 718 in a 3.5 wt.% NaCl solution is investigated. Severe work hardening and high compressive residual stress are generated with surface smoothing and microstructure evolution in terms of formation of nano-grains and nano-twins in the near surface region after machine hammer peening. Electrochemical tests results show that machine hammer peening has a beneficial influence on the corrosion resistance, indicated by a significant increase of the critical pitting potential (+134 mV) accompanied with lower corrosion current density and higher polarization resistance.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Deformation fields near a steady fatigue crack with anisotropic plasticity

In this work, from finite element simulations based on an irreversible, hysteretic cohesive interface model, a steady fatigue crack can be realized if the crack extension exceeds about twice the plastic zone size, and both the crack increment per loading cycle and the crack bridging zone size are smaller than the plastic zone size. The corresponding deformation fields develop a plastic wake behind the crack tip and a compressive residual stress field ahead of the crack tip. In addition, the Hill’s plasticity model is used to study the role of plastic anisotropy on the retardation of fatigue crack growth and the elastic strain fields. It is found that for Mode-I cyclic loading, an enhanced yield stress in directions that are inclined from the crack plane will lead to slower crack growth rate, but this retardation is insignificant for typical degrees of plastic anisotropy. Furthermore, these results provide key inputs for future comparisons to neutron and synchrotron diffraction measurements that provide full-field lattice strain mapping near fracture and fatigue crack tips, especially in textured materials such as wrought or rolled Mg alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Environmental influence on cracking and debonding of electrically conductive adhesives

Electrically conductive adhesives (ECAs) are starting to replace metallic solders in recent designs of photovoltaic (PV) modules. This transition represents a significant material change, and a proper understanding of the durability and reliability of the new interconnect needs to be established. This paper presents our continued work on developing a degradation model for ECA interconnects in PV modules. Here, we characterize the fracture mechanics properties of an epoxy-based ECA, for both critical and subcritical, mode I and mode II loading conditions. Emphasis is on the influence of different environmental conditions such as temperature and humidity. We use the Finite Element Method to account for residual stresses, induced by temperature changes and moisture absorption, and correct the apparent fracture toughness. We found that high moisture levels not only can weaken the fracture resistance of the ECA interconnect, but can also promote subcritical debonding at significantly lower driving forces than in dry environments.

42 ENGINEERING↗
DOE OSTI2025

Development, validation, and verification of multi-pass thermo-mechanical welding simulations using the open-source MOOSE framework: NeT TG4 benchmark weldment

This study develops and validates a sequentially coupled thermo-mechanical welding simulation for the three-pass 316L stainless steel NeT TG4 benchmark weldment using the open-source Multiphysics Object-Oriented Simulation Environment (MOOSE) and the Nuclear Engineering Material model Library (NEML). A diffused ellipsoidal heat source was calibrated against thermocouple data and weld macrographs to accurately model the fusion zone geometry and transient thermal fields. Material hardening is represented using the Lemaitre-Chaboche mixed isotropic-kinematic hardening model, while four annealing models - no annealing, single-stage at 1050 °C and 1300 °C, and two-stage at 800 °C/1300 °C - were implemented to assess the impact of annealing models on the accuracy of the predicted welding-induced plasticity, distortions, and residual stresses. The predictions were validated against experimental measurements and benchmarked against results from commercial software, demonstrating that thermo-mechanical MOOSE welding simulations achieve comparable accuracy with enhanced computational efficiency. This work highlights the potential of using open-source finite element frameworks like MOOSE for advanced manufacturing simulations.

Ji, Wendy [Australian Nuclear Science and Technolo↗
DOE OSTI2020

Structural stability of mechanically alloyed amorphous (FeCoNi) 70 Ti 10 B 20 under high-temperature and high-pressure

Nanostructured (FeCoNi) 70 Ti 10 B 20 (at%) alloy was synthesized by mechanical alloying from elemental powder mixture of Fe, Co, Ni, Ti and B using ball milling. The effect of ball milling time on the evolution of structure and morphology was investigated by X-ray diffraction, scanning and transmission electron microscopy and differential thermal analysis. It was observed that the formation of solid solution of (FeCoNi) 70 Ti 10 B 20 started from the very onset of the milling process. Crystallite size and lattice strains seemed to be leveled off after 20 h of milling with no further major changes. The milling process for longer periods introduced severe plastic deformations causing formation of amorphous phase of (FeCoNi) 70 Ti 10 B 20 . The amorphous alloy composition was confirmed by energy dispersive X-ray spectroscopy analysis that showed an excellent homogeneity of the alloying elements. The phase stability of the mechanically alloyed amorphous sample was further verified by employing high-temperature and high-pressure studies. The alloy samples heat-treated at 700 °C revealed crystallization of the amorphous phase. However, synchrotron-based high-pressure ambient temperature X-ray diffraction studies confirmed that the amorphous phase of the alloy remained stable up to the pressure of 30 GPa. Here, the 50 h milled sample after being annealed at 350 °C showed improvement in the soft magnetic properties of the alloy, which was due to the probable elimination of the residual stress in the amorphous phase of the alloy powders.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Graded microstructure and mechanical properties of spark plasma sintered Fe-Cr alloys

Developing graded microstructure and mechanical properties is critical for accelerating the design and optimization of structural materials for a wide range of applications. Here, in this study, Fe-Cr alloys were fabricated by spark plasma sintering (SPS) technique. The microstructure, microhardness, and tensile properties of the as-fabricated and thermally annealed variants were investigated. Graded grain structures were created in the as-fabricated cylinders along both axial and radial directions. Grain size was gradually reduced from the sample periphery to the center. Microhardness measurements reveal a gradual decrease of hardness towards the periphery of the samples. The as-fabricated Fe-Cr alloys show a desired combination of tensile strength and elongation, primarily due to the formation of a high density of oxides, voids, dislocations, and grain boundaries. After in-situ thermal annealing at 600 °C under 60 MPa for 2 h using SPS, the Fe-Cr alloys underwent minimal grain growth, and the graded grain structures were retained. The hardness was more uniformly distributed in the annealed variants, and the tensile strength was reduced with an increase in the total elongation, which is attributed to the dissolution of nano-sized oxide particles and the relief of the residual stress. This study demonstrates that SPS coupled with subsequent heat treatment can tailor the graded microstructure and control the mechanical properties of Fe-Cr alloys, showing potential applications in other alloy systems.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Mechanical behavior of bimetallic stainless steel and gray cast iron repairs via directed energy deposition additive manufacturing

The utility of gray cast iron in engine components remains tied to the mechanical performance and cost. Repair and remanufacturing of castings offer economical and sustainable benefits; however, high thermal input from traditional fusion-based welding is unable to restore the original mechanical quality owing to brittle microstructures and porosity formed in situ. Directed energy deposition (DED) is an additive manufacturing method that has received considerable interest for repairs owing to the highly controllable nature of the process. Despite this, few works have connected the effect of DED parameters on actual interfacial strength. Consequently, distinct DED parameter combinations were identified to maximize the strength and fatigue life of the repaired cast iron. Further, high speed melt pool imaging and residual stress measurements are provided to aid in the understanding of the metallurgical quality and strength seen in these structures. In general, higher scanning speeds and lower thermal gradients promoted comparable tensile strength to that of the original gray cast iron. The results presented here provide a foundation to tune in the DED process to generate the required mechanical quality as a starting point for future process advancements.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Machine-to-machine variability of roughness and corrosion in additively manufactured 316L stainless steel

Numerous studies on the corrosion response of metal AM have been conducted. Nonetheless, the specimens being tested are commonly ground or polished to remove the outer as-built surface. If metal AM is truly going to be employed as a transformative technology that can produce complex shapes that do not require traditional machining, then the material needs to be evaluated in the as-built state. The reality is that AM alloys have shown significant inconsistencies regarding as-built surface texture, topology, and residual stress. One metric that has shown significant unpredictability in the literature is the susceptibility to localized corrosion of typically passive alloys, such as stainless steel (SS). There are a large number of studies that have attempted to understand the corrosion response of metal AM materials, but these studies are typically performed on materials that have been printed on a single machine and often mechanically polished to a smooth finish. This study compares the corrosion response of as-built AM, laser-beam powder bed fusion (LB-PBF), 316L SS parts that have been fabricated on five different machines. The majority of this work focused on understanding the susceptibility to localized corrosion of AM metals with respect to machine-dependent variables, namely surface roughness, and build angle. Surface roughness data was collected using scanning white light triangulation, laser scanning confocal microscopy, and coherence scanning interferometry. The results show that there is significant variability (p two-tail < 0.05) in the susceptibility to local corrosion initiation of LB-PBF 316L SS samples built on different machines. Surface oxides were probed with electron dispersive spectroscopy and revealed that variations in local corrosion susceptibility likely arise from differences in the stability of the passive film caused by chemical segregation, unique microstructure, and tortuous roughness features at the as-built surfaces. The variability of roughness and corrosion properties from test samples printed on different machines was corroborated by property measurements performed at five different testing sites, proving reproducibility of the data. Most importantly, this study shows that if the as-built surface layer is removed through grinding or electropolishing the machine-to-machine variation observed in the corrosion susceptibility is reduced.

36 MATERIALS SCIENCE↗