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At least 1,225 records · Page 68
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Outlook on texture evolution in additively manufactured stainless steels: Prospects for hydrogen embrittlement resistance, overview of mechanical, and solidification behavior

Abstract Realizing application specific manufacture with fusion-based additive manufacturing (F-BAM) processes requires understanding of the physical phenomena that drive evolution of microstructural attributes, such as texture. Current approaches for understanding texture evolution in F-BAM are majorly considerate of the phenomena occurring only during solidification. This hinders the comprehensive understanding and control of texture during F-BAM. In this perspective article, we discuss several physical phenomena occurring during and after solidification that can determine texture in F-BAM processed stainless steels (SS). A crystal plasticity-coupled hydrogen adsorption-diffusion modeling framework is also leveraged to demonstrate the prospects of grain boundary engineering with F-BAM for enhanced hydrogen embrittlement resistance of SS. Implications of varying thermokinetics in F-BAM for solidification behavior of SS are discussed. Additionally, microstructural attributes that are key to high temperature mechanical performance of SS are highlighted. Considerations as outlined in this perspective article will enable grain boundary engineering and application specific microstructural design of SS with F-BAM. Graphical abstract

36 MATERIALS SCIENCE↗
DOE OSTI2020

An Accelerated Creep Testing Program For Nickel Based Superalloys

In order to improve the energy production within the United States, new materials are developed with the goal of increased functionality. These materials are required to perform at extreme pressures and temperatures (up to and beyond 200MPa and 650â??) as well as be sustainable beyond 105 hours. Before developing these materials into components for power generation, mechanical testing is required to better understand the behavior of these materials at various loads and temperatures. The longest of these tests is the conventional creep test which is a real time test that can beyond 105 hours depending on service conditions. Hundreds of specimens must be tested before being approved for use in power generation, but it is extremely difficult to rapidly qualify when each material is required to exceed 105 hours making testing through conventional means unfeasible. While others have designed accelerated testing methods to help qualify materials, many of these experiments use an empirical approach that requires test data to fit already existing creep data. In this study, an accelerated creep test called the stepped isostress method (SSM) is then applied to wrought Inconel 718 (IN 718) specimens. A test matrix is designed using deformation mechanism maps, time-temperature-transformation diagrams, and time-temperature-precipitation diagrams, in order to ensure that microstructurally, the accelerated creep tests fail similarly to the conventional creep tests. The data from the stepped isostress method is then applied to the McVetty and Sin-hyperbolic (Sinh) constitutive models in order to generate a creep master curve. The results from the model fits are then compared to the conventional creep data done from experiments as well as from the NIMS database for Inconel 718. Optical microscopy and scanning electron microscopy are used to compare the evolution of the microstructure from the conventional creep and accelerated creep tests. It is found that using the Sinh model on the accelerated creep data provides reasonable creep rupture predictions when compared to the scatter band of creep tests. It was also observed that the microstructural evolution between the SSM experiments and creep tests were very similar in terms of the volume fraction of precipitates and phases.

Mach, Robert↗
DOE OSTI2021

High Entropy Alloys: Irradiation

High entropy alloys (HEAs) have been considered as structural materials for nuclear applications due to their promising mechanical properties and radiation resistance. For this purpose, irradiation-induced defect evolution and microstructure change have been characterized to evaluate the irradiation performance of different HEAs. This article reviews recent advances in understanding the irradiation response of HEAs, including the effect of disordered states on the defect energy landscape and defect evolution, irradiation-induced microstructure changes, void swelling, phase stability, mechanical properties under irradiation, as well as the He irradiation effects.

Zhao, Shijun↗
DOE OSTI2021

Understanding the phase transformation mechanisms that affect the dynamic response of Fe-based microstructures at the atomic scales

Large-scale molecular dynamics (MD) simulations were carried out to investigate the shock-induced evolution of microstructure in Fe-based systems comprising single-crystal and layered Cu/Fe alloys with a distribution of interfaces. The shock compression of pure single-crystal Fe oriented along [110] above a threshold pressure results in a BCC (α)→HCP (ε) phase transformation behavior that generates a distribution of ε phase variants in the phase transformed region of the microstructure behind the shock front. The propagation of the release wave through a phase transformed ε phase causes a reverse ε→α phase transformation and renders a distribution of twins for the [110] oriented Fe that serve as void nucleation sites during spall failure. The simulations reveal that the α→ε→α transformation-induced twinning for shock loading along the [110] direction is due to a dominant ε phase variant formed during compression that rotates on the arrival of the release wave followed by a reverse phase transformation to twins in the α phase. The modifications in the evolution of the ε phase variants and twins in Fe behavior are also studied for Cu–Fe layered microstructures due to the shock wave interactions with the Cu/Fe interfaces using a newly constructed Cu–Fe alloy potential. Here, the MD simulations suggest that interfaces affect the observed variants during shock compression and, hence, distributions of twins during shock release that affects the void nucleation stresses in the Fe phase of Cu/Fe microstructures.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Effect of friction stir welding and self-ion irradiation on dispersoid evolution in oxide dispersion strengthened steel MA956 up to 25 dpa

Here, the effect of ion irradiation on the microstructure of oxide dispersion strengthened (ODS) MA956 steel, before and after friction stir welding (FSW), was studied. Both the base material (BM) and welded stir zone (SZ) were irradiated with 5 MeV Fe ++ ions at 450 °C up to 25 displacements per atom (dpa). Characterization was performed using scanning transmission electron microscopy (STEM) and atom probe tomography (APT), with particular emphasis on the Y—Al—O dispersoid characteristics and dislocation microstructures. After irradiation, the dispersoids in the BM increased in diameter and decreased in number density, which was explained by an Ostwald ripening mechanism. FSW caused significant coarsening and agglomeration of the dispersoids. After irradiation, both the diameter and number density of the SZ dispersoids increased, which was explained by an irradiation-enhanced diffusion mechanism. Dislocation loop and network behavior was also characterized and large dislocation loops of ≈20 nm diameter formed by 1 dpa in both the BM and SZ samples, whereas the network density remained nearly constant with irradiation.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Effect of powder layer thickness on the microstructural development of additively manufactured SS316

By Increasing the powder layer thickness we could increase material deposition rates and reduce build times during laser powder bed fusion (LPBF). However, increasing the powder layer thickness could also negatively affect the local melting and subsequent microstructure of the printed material. This study systematically investigated, for the first time, the defect evolution and microstructural changes of LPBF stainless steel 316 (SS316) processed by using various powder layer thicknesses of 40, 80, and 120 μm while also varying the laser dwell time for the pulsed laser. Through image analysis, the pore density was found to increase with increasing powder layer thickness, particularly when the dwell time was too high or too low. The maximum achievable density (>99%) was found over a wide processing window when using the smallest powder layer thickness of 40 μm between dwell times of 60 and 100 μs. Increasing the powder layer thicknesses to 80 and 120 μm resulted in maximum densities of 98.7 and 96.8%, respectively, but the window for acceptable laser dwell times that could achieve these densities narrowed considerably. A microstructural analysis of the melt pools was performed to measure the melt pool depths and widths, both of which increased with increasing dwell time. However, increasing the powder layer thickness did not affect the melt pool depth and only minorly affected the width. A sub-grain cellular structure distinguished the melt pool boundaries. The cell size increased with increasing dwell time and decreasing powder layer thickness. Moreover, the cell size was used to calculate a cooling rate that had a magnitude of 10 7 K/s and increased with increasing powder layer thickness.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Compositionally-Driven Formation Mechanism of Hierarchical Morphologies in Co-Deposited Immiscible Alloy Thin Films

Co-deposited, immiscible alloy systems form hierarchical microstructures under specific deposition conditions that accentuate the difference in constituent element mobility. The mechanism leading to the formation of these unique hierarchical morphologies during the deposition process is difficult to identify, since the characterization of these microstructures is typically carried out post-deposition. We employ phase-field modeling to study the evolution of microstructures during deposition combined with microscopy characterization of experimentally deposited thin films to reveal the origin of the formation mechanism of hierarchical morphologies in co-deposited, immiscible alloy thin films. Our results trace this back to the significant influence of a local compositional driving force that occurs near the surface of the growing thin film. We show that local variations in the concentration of the vapor phase near the surface, resulting in nuclei (i.e., a cluster of atoms) on the film’s surface with an inhomogeneous composition, can trigger the simultaneous evolution of multiple concentration modulations across multiple length scales, leading to hierarchical morphologies. We show that locally, the concentration must be above a certain threshold value in order to generate distinct hierarchical morphologies in a single domain.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Effect of post-deposition heat treatment on microstructure and mechanical properties of NASA HR-1 cold spray coatings

The primary goal of this work was to examine the impact of heat treatment on the evolution of microstructure and mechanical properties of NASA HR-1 cold spray coatings. Coatings were produced employing a high pressure cold spray system using N2 and He process gases and the effect of process gas and deposition temperature on the microstructure and mechanical properties of the coatings was examined. Microstructural characterization was performed using optical microscopy, scanning electron microscopy, micro X-ray computed tomography, and electron backscatter diffraction. NASA HR-1 coatings produced with He process gas exhibited improved plastic deformation and resulted in the lowest porosity compared to those deposited with N2 process gas. All coatings showed brittle failure with limited ductility in the as-deposited condition. Heat treatment of the NASA HR-1 cold spray coatings was performed at 550°C and 950°C for 1 h to improve the mechanical strength of the coatings. Heat treatment improved the particle bonding and enhanced the mechanical properties of the cold spray coatings. Heat treatment performed at 550°C resulted in higher mechanical strength of coatings, whereas the heat treatment performed at 950°C resulted in recrystallized microstructure and improved ductility of the coatings. However, heat treatment at 950°C resulted in forming the Eta (η) phase and Ni-Ti intermetallics in all the NASA HR-1 cold spray coatings. Here, the overall results suggest that using He as process gas contributed to reduced porosity and enhanced mechanical properties of the cold spray coatings.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2017

In Situ X-ray Microtomography of Stress Corrosion Cracking and Corrosion Fatigue in Aluminum Alloys

Structural materials are subjected to combinations of stress and corrosive environments that work synergistically to cause premature failure. Therefore, studies on the combined effect of stress and corrosive environments on material behavior are required. Existing studies have been performed in two dimensions that are inadequate for full comprehension of the three-dimensional (3D) processes related to stress corrosion cracking (SCC) and corrosion-fatigue (CF) behavior. Recently, x-ray synchrotron tomography has evolved as an excellent technique to obtain the microstructure in 3D. Moreover, being nondestructive in nature, x-ray synchrotron tomography is well suited to study the evolution of microstructure with time (4D, or fourth dimension in time). Furthermore, this article presents our recent 4D studies on SCC and CF of Al 7075 alloys using x-ray synchrotron tomography.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Investigation of annealing temperature on microstructure and texture of Fe-19Cr-2Mo-Nb-Ti ferritic stainless steel

Highlights: • Fe-19Cr-2Mo-Nb-Ti ferritic stainless steel was investigated. • Shear bands provided recrystallization nucleation sites. • Annealing temperature can affect microstructure and texture. • r-bar increased to a maximum value (1.69) and then decreased to 1.42. - Abstract: The evolution of microstructure and texture of Fe-19Cr-2Mo-Nb-Ti ferritic stainless steel annealed at different temperatures was investigated using a combination of X-ray diffraction (XRD) and electron backscatter diffraction (EBSD). EBSD investigations confirm that the in-grain shear bands provide more recrystallization nucleation sites to γ-fiber recrystallization grains with high Taylor factor orientations during cold rolling requiring further annealing for a more homogenous equiaxied grain structure. As the annealing temperatures increase, the grains in center layer are oriented towards {110}∥ND, and the recrystallization grains at 1050 °C are dominated by the uniform and equiaxial γ-fiber grains favourable for the improvement of r-values, while the occurrence of {100} <011> texture detrimental to r-values indicates that an exorbitant annealing temperature can reduce the intensity of γ-fiber textures affecting the formability, accordingly, the average plastic strain ratio of ferritic stainless steel increases sharply up to a maximum value (1.69) and then decreases to a certain value (1.42).

36 MATERIALS SCIENCE↗
DOE OSTI2018

Effect of Cold Rolling and Heat Treatment on Microstructure and Mechanical Properties of Ti-4Al-1Mn Titanium Alloy

Mechanical behavior of Ti-4Al-1Mn titanium alloy has been studied in annealed, cold-rolled and heat-treated conditions. Room temperature tensile strength as well as % elongation has been found to be low with increasing amount of cold rolling. Lowering of strength in cold worked condition is attributed to premature failure. However, the same has been mitigated after heat treatment. Significant effect of cooling media (air and water) from heat treatment temperature on microstructure was not found except for the degree of fineness of α plates. Optimum properties (strength as well as ductility) were exhibited by samples subjected to 15% cold rolling and heat treatment below β transus temperature, which can be attributed to presence of recrystallized microstructure. In cold worked condition, the microstructure shows fine fragmented α plates/Widmanstätten morphology with high dislocation density along with a large amount of strain fields and twinning, which gets transformed to recrystallized equiaxed microstructure and with plate-like morphology after near β heat treatment. Prior cold work is found to have a significant effect on mechanical properties supported by evolution of microstructure. Twinning is found to be assisting in deformation as well as in recrystallization through the formation of deformation and annealing twins during cold working and heat treatment. Fracture analysis of the tested sample with prior cold work and heat-treated condition revealed quasi-ductile failure as compared to only ductile failure features seen for samples heat treated without prior cold work.

36 MATERIALS SCIENCE↗
DOE OSTI2024

An approach to combine neutron and ion irradiation data to accelerate material qualification for nuclear reactors

Next-generation nuclear power plants are generally characterized by higher operating temperatures, increased neutron fluences and energies, and distinct corrosive coolant environments versus the existing light water reactor fleet. Whether using existing materials in new environments, newly developed materials tailored for these environments, or new manufacturing methods, the traditional decades-long approach for materials qualification does not facilitate rapid deployment. Ion irradiation has demonstrated success in reproducing material microstructure and select property evolution resulting from neutron irradiation with three to four orders of magnitude reduction in time and cost, making it an ideal candidate for accelerated irradiation testing. Because microstructure has a large impact on bulk material properties, limited neutron irradiation data at lower damage levels can in principle be combined with accelerated ion testing results and modeling and simulation to form an accurate prediction of microstructure evolution and select properties under different neutron irradiation conditions and at higher damage levels. The objective of this work is to present a conceptual framework of specific steps to fulfill several technical challenges associated with qualifying materials for performance in radiation environments on an accelerated time frame. A brief review of the regulatory landscape for materials in nuclear environments is presented, followed by additional overviews to understand the current state of the art for correlation of materials properties across radiation environments using experimental and computational methodologies. Finally, the roles of academia, national laboratories, and industry in the advancement of this accelerated materials qualification framework are discussed as a path forward, with possible case studies presented.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2018

Effect of niobium and phase transformation temperature on the microstructure and texture of a novel 0.40% C thermomechanically processed steel

Field emission scanning electron microscopy, electron backscatter diffraction (EBSD) and X-ray diffraction (XRD) have been employed to investigate the effect of niobium and phase transformation temperature on the evolution of microstructure and texture in a novel thermomechanically processed, medium‑carbon, low-alloy steel intended for slurry pipeline applications. Thermomechanical processing consisted of hot-rolling in the austenitic region with deformation both above the recrystallization limit temperature and below the recrystallization stop temperature. Immediately after rolling, specimens were directly quenched in water to two different temperatures of 560 °C and 420 °C and subsequently furnace cooled from those temperatures to simulate the cooling of coiled strip on a hot strip mill. The microstructure of samples quenched to 560 °C mostly comprised of upper bainite, whereas the samples quenched to 420 °C mainly consisted of lath-type lower bainite. The transformation texture of all samples at the mid-thickness position consisted of α, γ and ε-fibers with high intensities close to the transformed copper, transformed brass and rotated cube components. The addition of 0.013 wt% Nb refined the microstructure and sharpened the texture. The texture of the small fraction of retained austenite present in the final microstructures indicated that the main bcc texture components result from the brass and copper components in the parent austenite.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Materials Dynamics

The Materials Dynamics area of leadership focuses on understanding structure-properties-performance relationships for the extreme conditions of dynamic loading. This research encompasses controlled synthesis of materials to meet dynamic performance requirements and requires computational coupling across length and time scales for three-dimensional microstructure modeling. For this leadership area, we define dynamic loading as strain rates greater than 103/s. A key grand challenge of this area is to predict and measure the evolution of microstructural phases, defect structures, and electronic structure under dynamic conditions while also dynamically measuring local temperature to understand transition states. Solving this challenge will require agile, multidimensional data analysis and interpretation capability.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Materials Dynamics

The Materials Dynamics area of leadership focuses on understanding process-structure-properties-performance (PSPP) relationships for the extreme conditions of dynamic loading. This research encompasses controlled synthesis of materials to meet dynamic performance requirements and entails computational coupling across length and time scales for three-dimensional microstructure modeling. For this leadership area, we define dynamic loading as strain rates ≥ 10 3 /s and often, high pressures. A key grand challenge of this area is to predict and measure the evolution of microstructural phases, defect structures, and electronic structure under dynamic conditions while also measuring local temperature to understand transition states. Solving this challenge will require agile, multi-dimensional data analysis and interpretation capability.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Microstructure and microhardness of an Al-6061 metal matrix composite processed by high-pressure torsion

Disks of an Al-6061 metal matrix composite, reinforced with 10 vol.% Al{sub 2}O{sub 3} particles, were processed by high-pressure torsion (HPT) at room temperature for 1/4, 1/2, 1, 5 and 10 turns under an applied pressure of 6.0 GPa. The evolution of microstructure was investigated using optical microscopy and scanning electron microscopy. During HPT processing the average grain size within the aluminum matrix decreased from ∼ 35 μm in the unprocessed condition to ∼ 170 nm after processing through 10 turns but there was no significant effect on the size and distribution of the alumina particulate clusters. The values of the Vickers microhardness were recorded across the surface of each disk and then plotted as two-dimensional and three-dimensional color-coded contour maps. The results show the hardness increases from ∼ 56 Hv in the initial condition to ∼ 165 Hv after HPT for 10 turns. The results demonstrate that, as in many unreinforced metallic alloys, the evolution of hardness with strain exhibits strain hardening without any significant recovery. - Highlights: •The average grain size of the Al matrix was ~ 170 nm after processing for 10 turns. •No significant effect of HPT on the size and distribution of the Al{sub 2}O{sub 3} particles. •The evolution of microhardness demonstrates strain hardening without recovery. •The microhardness at low strains increases linearly from the center to the edge. •The microhardness at high strains becomes homogeneous with a saturation of ~ 170 Hv.

36 MATERIALS SCIENCE↗
DOE OSTI2017

In situ, 3D characterization of the deformation mechanics of a superelastic NiTi shape memory alloy single crystal under multiscale constraint

Microstructural elements in NiTi shape memory alloys (SMAs) – precipitates, phase boundaries, inclusions, grain boundaries – can be viewed as sources of multiscale constraint that influence their deformation response. In this paper, we characterized in situ, and in 3D, the deformation and the evolution of microstructure during a tension test in a superelastic NiTi specimen containing some of these sources of constraint. The method used was far-field high-energy X-ray diffraction microscopy (ff-HEDM), complemented by electron microscopy. We simulated the local stress state in the specimen using a microstructural model informed by the experimental data. Using these combined microstructure, deformation, and stress data, we report three phenomena, and relate them to specific sources of constraint. During initial elastic loading, axial lattice strain in austenite increased monotonically. On partial stress-induced phase transformation to martensite, the stress redistributed to both phases leading to a stress relaxation in austenite. The specimen contained a dense distribution of inclusions, which led to the activation of martensite habit plane variants that produce less than theoretical maximum transformation strain. Large Ni 4 Ti 3 precipitates potentially contributed to the poor transformation response. Under load, proportional gradients in local rotation and elastic stretch developed in the martensite phase, because of the constraint at phase interfaces. Finally, this combined ff-HEDM, electron microscopy, microstructural simulation toolbox provides a versatile method to understand the effect of constraint on inelastic deformation in other alloys with hierarchical microstructure.

36 MATERIALS SCIENCE↗
DOE OSTI2020

3D Characterization of the Columnar-to-Equiaxed Transition in Additively Manufactured Inconel 718

Additive manufacturing (AM) provides enormous processing flexibility, enabling novel part geometries and optimized designs. Access to a local heat source further permits the potential for local microstructure control on the scale of individual melt pools, which can enable local control of part properties. In order to design tailored processing strategies for target microstructures, models predicting the columnar-to-equiaxed transition must be extended to the high solidification velocities and complex thermal histories present in AM. Here, we combine 3D characterization with advanced modeling techniques to develop a more complete understanding of the solidification process and evolution of microstructure during electron beam melting (EBM) of Inconel 718. Full calibration of existing microstructure prediction models demonstrates the differences between AM processes and more conventional welding techniques, underlying the need for accurate determination of key parameters that can only be measured directly in 3D. The ability to combine multisensor data in a consistent 3D framework via data fusion algorithms is essential to fully leverage these advanced characterization approaches. Thermal modeling provides insight on microstructure development within isolated solidification events and demonstrates the role of Marangoni effects on controlling solidification behavior.

Polonsky, Andrew↗