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At least 127 records · Page 7

Harnessing metastability for grain size control in multiprincipal element alloys during additive manufacturing

Abstract Controlling microstructure in fusion-based metal additive manufacturing (AM) remains a significant challenge due to the many parameters that directly impact solidification condition. Multiprincipal element alloys (MPEAs), also known as high entropy alloys, offer a vast compositional space to design for microstructural engineering due to their chemical complexity and exceptional properties. Here, we use the FeMnCoCr system as a model platform for exploring alloy design in MPEAs for AM. By exploiting the decreasing stability of the face-centered cubic phase with increasing Mn content, we achieve notable grain refinement and breakdown of epitaxial columnar grain growth. We employ a multifaceted approach encompassing thermodynamic modeling, operando synchrotron X-ray diffraction, multiscale microstructural characterization, and mechanical testing to gain insight into the solidification physics and its ramifications on the resulting microstructure of FeMnCoCr MPEAs. This work aims toward tailoring desirable grain sizes and morphology through targeted manipulation of phase stability, thereby advancing microstructure control in AM applications.

Wakai, Akane↗

The Analysis of the General Performance and Mechanical Behavior of Unirradiated FeCrAl Alloys Before and After Welding

The present report summarizes and discusses the preliminary results for the in-depth characterization of the modern, nuclear-grade FeCrAl alloys currently under development. The alloys were designed for enhanced radiation tolerance and weldability, and the research is currently being pursued by the Department of Energy (DOE) Nuclear Energy Enabling Technologies (NEET) program. Last year, seven candidate FeCrAl alloys with well-controlled chemistry and microstructures were designed and produced; welding was performed under well-controlled conditions. The structure and general performance of unirradiated alloys were assessed using standardized and advanced microstructural characterization techniques and mechanical testing. The primary objective is to identify the best candidate alloy, or at a minimum to identify the contributing factors that increase the weldability and radiation tolerance of FeCrAl alloys, therefore enabling future generations of FeCrAl alloys to deliver better performance parameters. This report is structured so as to describe these critical assessments of the weldability; radiation tolerance will be reported on in later reports from this program.

36 MATERIALS SCIENCE↗

Science and Technology Review March 2012

This month's issue has the following articles: (1) Honoring a Legacy of Service to the Nation - The nation pays tribute to George Miller, who retired in December 2011 as the Laboratory's tenth director; (2) Life-Extension Programs Encompass All Our Expertise - Commentary by Bruce T. Goodwin; (3) Extending the Life of an Aging Weapon - Stockpile stewards have begun work on a multiyear effort to extend the service life of the aging W78 warhead by 30 years; (4) Materials by Design - Material microstructures go three-dimensional with improved additive manufacturing techniques developed at Livermore; (5) Friendly Microbes Power Energy-Producing Devices - Livermore researchers are demonstrating how electrogenic bacteria and microbial fuel cell technologies can produce clean, renewable energy and purify water; and (6) Chemical Sensor Is All Wires, No Batteries - Livermore's 'batteryless' nanowire sensor could benefit applications in diverse fields such as homeland security and medicine.

30 DIRECT ENERGY CONVERSION↗

Macro-micro multiscale modeling to assist the design of HPDC Al castings microstructure and alloys for EV super-large body structures (Phase 1)

Implementation of High Pressure Die Casting (HPDC) Aluminum (Al) body structures for high volume electrified vehicles (EV) to improve electric efficiency remains a key strategy within many original equipment manufacturer (OEM)s. In addition to high strength for safety requirements, superior Self-Piercing Riveting (SPR) performance is demanded for HPDC Al alloys to be compatible with high volume SPR joining. In this work, it is proposed to extend and validate an existing Contractor finite element multiscale macro-micro modeling approach to quantify the influence of the microstructure of HPDC alloys on the fracture strain/displacement under 3-point bend and clinch testing. The success of this work will allow to replace solution treatment stage with low energy consumption heat treatment (HT) processes, or to design new non heat treatable (NHT) HPDC Al alloys to eliminate HT requirements. Ultimately, this project will facilitate the application of HPDC Al alloys for super-large vehicle structures to significantly reduce vehicle weight, and thus improving energy efficiency. The purpose of this project is to extend and validate an existing finite element code, which is based on the Contractor developed macro-micro multi-scale modeling approach, to numerically simulate the three-point bending and clinch test and study the influences of material microstructural characteristics and phase properties on the rivetability. The macro-micro modeling approach begins with a sample scale model and identify the location, which is mostly prone to failure, the deformation history of the boundaries of that location calculated will be used to drive a microstructure-based sub-models where the material microstructure and microscale properties are considered. Using this approach, the wrap-bending failure for two Al alloys are correctly predicted for the first time. This will start with phase I effort of building a framework of macro-micro three point bending test and clinch test of Al10SiMgMn HPDC alloy in the as-cast and T7 heat treated conditions. Those results will then be validated with experimental test results. The phase II effort will involve the utilization of the knowledge learned in phase I to establish the quantitative correlation between the microstructure characteristics and the riveting performance, which will be further used to guide the optimization of HPDC Al alloy microstructure using heat treatment process to achieve sufficient rivetability to join large thin-wall HPDC alloys.

36 MATERIALS SCIENCE↗

Macro-micro multiscale modeling to assist the design of HPDC Al castings microstructure and alloys for EV super-large body structures (Phase 1)

Implementation of High Pressure Die Casting (HPDC) Aluminum (Al) body structures for high volume electrified vehicles (EV) to improve electric efficiency remains a key strategy within many original equipment manufacturers (OEM)s. In addition to high strength for safety requirements, superior Self Piercing Riveting (SPR) performance is demanded for HPDC Al alloys to be compatible with high volume SPR joining. In this work, it is proposed to extend and validate an existing Contractor finite element multiscale macro-micro modeling approach to quantify the influence of the microstructure of HPDC alloys on the fracture strain/displacement under 3-point bend and clinch testing. The success of this work will allow to replace solution treatment stage with low energy consumption heat treatment (HT) processes, or to design new non heat treatable (NHT) HPDC Al alloys to eliminate HT requirements. Ultimately, this project will facilitate the application of HPDC Al alloys for super-large vehicle structures to significantly reduce vehicle weight and thus improving energy efficiency. The purpose of this project is to extend and validate an existing f

99 GENERAL AND MISCELLANEOUS↗

A two-dimensional analytical unit cell model for redox flow battery evaluation and optimization

Cell performance optimization is important for improving the overall system efficiency of a redox flow battery. To gain better insights into key controlling factors of system efficiency, this work first proposed a theoretical model for a unit flow battery cell by extending a two-dimensional analytic model to a full battery cell. Such a model is then used for cell performance optimization after validating it with experimental and numerical modeling data. With the model results, the activation, equilibrium, and pump energy losses are identified as the dominant sources of battery energy losses. Further, a guideline for reducing these sources is also proposed. Following the guideline, the mass transport coefficient is shown as a key control factor of the equilibrium energy loss and Coulombic efficiency (CE). Approaches are then proposed to improve CE and the overall system efficiency. The mass transport is also revealed as the mechanism of pump rate optimization where an optimal pump rate significantly reduces the equilibrium energy loss. With both low equilibrium and pump energy losses, an optimal electrode porosity or specific area design can further improve a battery's system efficiency based on an optimal porosity predicted by the present model. The model also demonstrates distinct behaviors and overestimation in the system efficiency when reduced to a zero-dimensional model with neglected mass transport resistance. With the new model, the guideline, and new insights, this work provides a reliable and efficient tool for the evaluation and optimization of redox flow battery design in practical applications.

25 ENERGY STORAGE↗

Size effects of primary/secondary twins on the atomistic deformation mechanisms in hierarchically nanotwinned metals

A series of large-scale molecular dynamics simulations have been performed to investigate the tensile properties of nanotwinned (NT) copper with hierarchically twinned structures (HTS). For the same grain size d and the same spacing of primary twins {lambda}{sub 1}, the average flow stress first increases as the spacing of secondary twins {lambda}{sub 2} decreases, reaching a maximum at a critical {lambda}{sub 2}, and then decreases as {lambda}{sub 2} becomes even smaller. The smaller the spacing for {lambda}{sub 1}, the smaller the critical spacing for {lambda}{sub 2}. There exists a transition in dominating deformation mechanisms, occurring at a critical spacing of {lambda}{sub 2} for which strength is maximized. Above the critical spacing of {lambda}{sub 2}, the deformation mechanisms are dominated by the two Hall-Petch type strengthening mechanisms: (a) partial dislocations emitted from grain boundaries (GBs) travel across other GBs and twin boundaries (TBs); (b) partial dislocations emitted from TBs travel across other TBs. Below the critical spacing of {lambda}{sub 2}, the deformation mechanism is dominated by the two softening mechanisms: (a) Partial dislocations emitted from boundaries of the primary twins travel parallel to the TBs of the secondary twins, leading to detwinning of the secondary twins; (b) Boundaries of the primary twins shift entirely, leading to thickening in one part of primary twins and thinning in the other part of primary twins. The present results should provide insights to design the microstructures for reinforcing the mechanical properties in the NT metals with HTS.

36 MATERIALS SCIENCE↗

The effects of microstructure on propagation of laser-driven radiative heat waves in under-dense high-Z plasma

This work was motivated by previous findings that the measured laser-driven heat front propagation velocity in under-dense TiO 2 /SiO 2 foams is slower than the simulated one [Pérez et al., Phys. Plasmas 21, 023102 (2014)]. In attempting to test the hypothesis that these differences result from effects of the foam microstructure, we designed and conducted an experiment on the GEKKO laser using an x-ray streak camera to compare the heat front propagation velocity in “equivalent” gas and foam targets, that is, targets that have the same initial density, atomic weight, and average ionization state. In this article, we first discuss the design and the results of this comparison experiment. To supplement the x-ray streak camera data, we designed and conducted an experiment on the Trident laser using a new high-resolution, time-integrated, spatially resolved crystal spectrometer to image the Ti K-shell spectrum along the laser-propagation axis in an under-dense TiO 2 /SiO 2 foam cylinder. We discuss the details of the design of this experiment, and present the measured Ti K-shell spectra compared to the spectra simulated with a detailed superconfiguration non-LTE atomic model for Ti incorporated into a 2D radiation hydrodynamic code. Finally, we show that there is indeed a microstructure effect on heat front propagation in under-dense foams, and that the measured heat front velocities in the TiO 2 /SiO 2 foams are consistent with the analytical model of Gus'kov et al. [Phys. Plasmas 18, 103114 (2011)].

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Polarization Mechanisms in P(VDF-TrFE) Ferroelectric Thin Films

Ferroelectric polymers have amassed tremendous attention due to several attractive properties including high breakdown strength, low dielectric loss, relatively fast charge/discharge rates and greater flexibility than their ceramic counterparts. In order to achieve enhanced energy efficiency in high-energy storage capacitor applications, it is desirable to obtain slim polarization hysteresis loops for ferroelectric polymer films. Here, it has been demonstrated that promotion of large crystallites and γ phase content through thermal annealing provides a cost-effective way to obtain a quasi-linear polarization response in a PVDF co-polymer thin film. The polarization mechanisms underlying a thin hysteresis loop in the thermally annealed film are elucidated using direct experimental insights from in situ synchrotron diffraction with two-dimensional detection. It has been demonstrated that the susceptibility for electric-field-induced structural changes is higher in the defective ferroelectric γ phase than the polar phase β, due to a higher flexibility for accommodation of gauche bond along the carbon chain. In addition, the polymer chains in the γ phase also exhibit a range of different responses depending on their orientations with respect to the electric field. These conclusions are broadly significant as they provide a fundamental basis for rational design of phase assemblages to obtain tailor-made properties in ferroelectric polymer films.

36 MATERIALS SCIENCE↗

Attribution of heterogeneous stress distributions in low-grain polycrystals under conditions leading to damage

In high-purity polycrystalline metallic materials, voids tend to favor grain boundaries as nucleation sites due to the elevated stress states produced by granular interactions and the weakened grain boundary from the relative atomic disorder. To quantify the key factors of this elevated stress state, simple compression of a small multi-grain cylinder of body-centered cubic tantalum was simulated using a single crystal plasticity model that incorporates non-Schmid effects. Four increasingly complex synthetic microstructures were created to tractably incorporate grain boundary interactions, and a statistically significant number of combinations were performed by varying the initial crystallographic orientations of the microstructure. Most of these simulations produce the maximum von Mises stress on a grain boundary and less frequently at the multi-grain junctions. To build a statistical model for the maximum von Mises stress at the grain boundary, physically based features that could contribute to the elevated stress state were selected. Then, a learning algorithm based on information theory was used to identify which of these features contributed the most information to the data set. The identified features include a grain’s propensity to accommodate both elastic and plastic deformations and their directional components. The misalignment of the direction of each grain’s mechanical response was found to be strongly correlated to the magnitude of the stress near the grain boundary. For all of the synthetic microstructures, the statistical models produce a residual distribution that is nearly Gaussian with a variance of, at most, 10% of the prior distribution. The successful performance of the statistical model implies the correct identification of the physical features that cause severe stress localization in polycrystalline materials. The statistical models constructed here can be used to formulate a physically motivated void nucleation model which is sensitive to a microstructure’s propensity to produce elevated stress states. As a result, these statistical models also enable the design of material microstructures, in which the crystallographic orientation is chosen to resist void nucleation.

36 MATERIALS SCIENCE↗

Damage initiation and evolution in Al-Si layered microstructures under shock loading conditions at atomic scales

Designing materials with microstructural features like multiphase interfaces have shown significant promise for usage in the next generation defense and nuclear applications. The dynamic response of these interfaces in extreme environments is observed to vary with the deformability of individual phases, which could subsequently alter the favored damage nucleation sites related to spall failure. Here, we investigate the role of spacing of interfaces in a nanocrystalline layered Aluminum-Silicon system on the shock wave propagation behavior, and microstructural and defect evolution using classical molecular dynamics simulations. The simulations are carried out with different hypothetical Al/Si microstructures including variations in the distribution of Si grains as layers in a nanocrystalline Al matrix. The molecular dynamics simulations suggest that spall failure is preferentially initiated at Al/Si interfaces. In addition, for the same system volume and same concentration of Si, a higher number of layers is marked by an increase in shock wave velocity and reduced resistance to spall failure.

36 MATERIALS SCIENCE↗

Role of Sink Density in Nonequilibrium Chemical Redistribution in Alloys

Nonequilibrium chemical redistribution in open systems submitted to external forces, such as particle irradiation, leads to changes in the structural properties of the material, potentially driving the system to failure. Such redistribution is controlled by the complex interplay between the production of point defects, atomic transport rates, and the sink character of the microstructure. In this work, we analyze this interplay by means of a kinetic Monte Carlo (KMC) framework with an underlying atomistic model for the Fe-Cr model alloy to study the effect of ideal defect sinks on Cr concentration profiles, with a particular focus on the role of interface density. We observe that the amount of segregation decreases linearly with decreasing interface spacing. Within the framework of the thermodynamics of irreversible processes, a general analytical model is derived and assessed against the KMC simulations to elucidate the structure-property relationship of this system. Interestingly, in the kinetic regime where elimination of point defects at sinks is dominant over bulk recombination, the solute segregation does not directly depend on the dose rate but only on the density of sinks. Furthermore, this model provides new insight into the design of microstructures that mitigate chemical redistribution and improve radiation tolerance.

36 MATERIALS SCIENCE↗

Control the polarization state of light with symmetry-broken metallic metastructures

Controlling the polarization state, the transmission direction, the amplitude and the phase of light in a very limited space is essential for the development of on-chip photonics. Over the past decades, numerous sub-wavelength metallic microstructures have been proposed and fabricated to fulfill these demands. In this article, we review our efforts in achieving negative refractive index, controlling the polarization state, and tuning the amplitude of light with two-dimensional (2D) and three-dimensional (3D) microstructures. We designed an assembly of stacked metallic U-shaped resonators that allow achieving negative refraction for pure magnetic and electric responses respectively at the same frequency by selecting the polarization of incident light. Based on this, we tune the permittivity and permeability of the structure, and achieve negative refractive index. Further, by control the excitation and radiation of surface electric current on a number of 2D and 3D asymmetric metallic metastructures, we are able to control the polarization state of light. It is also demonstrated that with a stereostructured metal film, the whole metal surfaces can be used to construct either polarization-sensitive or polarization-insensitive prefect absorbers, with the advantage of efficient heat dissipation and electric conductivity. Our practice shows that metamaterials, including metasurface, indeed help to master light in nanoscale, and are promising in the development of new generation of photonics.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

Creep-induced microstructural evolution in a nickel-based superalloy designed for advanced ultra-supercritical boilers

Highlights: • Microstructural evolution of a nickel-based superalloy during long-term creep was investigated. • Precipitate-free zones (PFZs) widely arose near the grain boundary under stress. • The coarsened and elongated particles in the PFZs were identified as γ′ precipitates. • The boundary movement plays a role in evolution of grain boundary precipitates. - Abstract: Long-term microstructural stability is a major concern for candidate materials used in advanced ultra-supercritical (A-USC) power plants. In the present work, precipitation behavior of a nickel based superalloy designed for A-USC boilers, with a base composition of Ni-25Cr-20Co, was investigated during long-term thermal exposure under different stresses at 1043 K. The results showed that the coarsening of γ′ precipitates in the grain interior had occurred during thermal exposure in the presence and absence of stress. The microstructure around grain boundary was altered remarkably under stress. The precipitate-free zones (PFZs) commonly existed near the grain boundary in the gauge sections of specimens after long-term creep. Coarsened and elongated particles in the PFZs were identified as γ′-Ni{sub 3} (Ti, Al) precipitates by chemical composition analysis and diffraction pattern. Furthermore, the morphology and distribution of MC-type carbides have no significant changes observed due to their good stability, but discontinuous M{sub 23}C{sub 6} appeared under stress, due to formation of PFZs resulting in dissolution of the adjacent M{sub 23}C{sub 6}. Besides, the creep-rupture mechanism was discussed to explore a potential approach for improving creep properties.

36 MATERIALS SCIENCE↗

Microstructure Characterization and Modeling for Improved Electrode Design

As part of DOE's Computer-Aided Engineering of Batteries Program, the National Renewable Energy Laboratory is developing detailed models capturing the influence of lithium-ion battery electrode design, recipe and processing on the electrode's microstructure and relating that microstructure to device-level performance. Given the difficulty in obtaining 3D microstructural images of the electrode's inert components, team member Purdue University developed an algorithm to computationally generate the so-called carbon-binder domain (CBD) for any given recipe. Mesoscale models explore the device-level impact of the CBD phase on multiple idealized and actual electrode geometries. With the inclusion of this CBD phase, microstructure models are used to predict the tortuosity of 14 different graphite and NMC electrode designs. Tortuosity predictions are shown in good agreement with experimental direct measurement and electrochemical rate studies.

25 ENERGY STORAGE↗

Explicit Backscattering Coefficient for Ultrasonic Wave Propagating in Hexagonal Polycrystals with Fiber Texture

Hexagonal polycrystalline materials such as titanium, zirconium and magnesium are common in engineering structures like car bodies and airplane engines. These components are usually specially designed in microstructure level to guarantee desired mechanical properties, so microstructure characterization is of great importance to the optimization of manufacturing processes. Compared with traditional destructive characterization methods like scanning electron microscopy (SEM), the ultrasonic approach is nondestructive and cost-effective. Although some progress has been made in ultrasonic microstructure characterization of polycrystal aggregates of hexagonal grains, some factors like macro texture and grain size distribution associated with realistic microstructures were not accounted for yet. Targeting one common texture component for hexagonal polycrystalline materials, {0001} basal fiber texture, this paper derived the explicit backscattering coefficient for aggregates of ellipsoidal grains through one texture parameter and obtained an analytical backscattering coefficient for microstructures with various grain size distributions. In this study, the basal fiber texture was quantified by the 1D Gaussian orientation distribution function (ODF), which merely includes one texture parameter, and its relationship with generalized spherical harmonics ODF was also addressed. Moreover, explicit expressions for effective elastic moduli and elastic constant covariances were derived. Furthermore, some computational examples were given to demonstrate the impacts of texture, frequency, grain geometry and grain size distribution on backscattering behavior. The theoretical results in this study will greatly benefit the later ultrasonic microstructure characterization of hexagonal polycrystalline materials.

42 ENGINEERING↗

Processing Techniques for ODS Stainless Steels

Oxide dispersion-strengthened (ODS) alloys have been studied extensively, in part as a response to the need to develop the high-temperature materials that are required for energy efficient systems. ODS stainless steels, in particular, are of technological interest because of their high ductility and high strength at elevated temperatures, which when combined with their resistance to corrosion, render them ideal for many applications that require extreme performance quality. Survey of the published literature reveals that efforts have been devoted to incorporate specific strengthening mechanisms in order to meet demanding performance criteria for ODS alloys. As a result, a number of novel processing approaches have been developed in an effort to design distinct microstructures that can enhance the performance of ODS alloys. In the current paper, various techniques used to manufacture ODS stainless steel alloys are compared and summarized on the basis of a literature search, and results are contrasted with selected experimental data obtained by the authors. In particular, cryomilling, water-atomization, and melt-spinning processes are described in detail as three novel approaches that can be effectively used to distribute nanometric oxides in 316L stainless steel matrix. The microstructural features, mechanical properties, and sintering behavior of the fabricated materials are described and discussed. The critical processing parameters for each processing technique are discussed with reference to the properties of the material. The versatility and potential challenges of the individual techniques are also described and contrasted.

36 MATERIALS SCIENCE↗

High entropy alloys: A focused review of mechanical properties and deformation mechanisms

The high-entropy alloy (HEA) concept was based on the idea that high mixing entropy can promote formation of stable single-phase microstructures. During the past 15 years, various alloy systems have been explored to identify HEA systems with improved property combinations, leading to an extraordinary growth of this field. In the large pool of alloys with varying characteristics, the first single-phase HEA with good tensile properties, the equiatomic CrMnFeCoNi alloy has become the benchmark material, and it forms the basis of much of our current fundamental understanding of HEA mechanical behavior. As the field is evolving to the more broadly defined complex concentrated alloys (CCAs) and the available data in the literature increase exponentially, a fundamental question remains unchanged: how special are these new materials? In the first part of this review, select mechanical properties of HEAs and CCAs are compared with those of conventional engineering alloys. This task is difficult because of the limited tensile data available for HEAs and CCAs. Additionally, the wider suite of mechanical properties needed to assess structural materials is woefully lacking. Nonetheless, our evaluations have not revealed many HEAs or CCAs with properties far exceeding those of conventional engineering alloys, although specific alloys can show notable enhancements in specific properties. Consequently, it is reasonable to first approach the understanding of HEAs and CCAs through the assessment of how the well-established deformation mechanisms in conventional alloys operate or are modified in the presence of the high local complexity of the HEAs and CCAs. The second part of the paper provides a detailed review of the deformation mechanisms of HEAs with the FCC and BCC structures. For the former, we chose the CrMnFeCoNi (Cantor) alloy because it is the alloy on which the most rigorous and thorough investigations have been performed and, for the latter, we chose the TiZrHfNbTa (Senkov) alloy because this is one of the few refractory HEAs that exhibits any tensile ductility at room temperature. As expected, our review shows that the fundamental deformation mechanisms in these systems, and their dependence on basic physical properties, are broadly similar to those of conventional FCC and BCC metals. The third part of this review examines the theoretical and modeling efforts to date that seek to provide either qualitative or quantitative understanding of the mechanical performance of FCC and BCC HEAs. Since experiments reveal no fundamentally new mechanisms of deformation, this section starts with an overview of modeling perspectives and fundamental considerations. Next, the review turns to the evolution of modeling and predictions as compared to recent experiments, highlighting both successes and limitations. Finally, in spite of some significant successes, important directions for further theory development are discussed. Overall, while the individual deformation mechanisms or properties of the HEAs and CCAs are not, by and large, “special” relative to conventional alloys, the present HEA rush remains valuable because the compositional freedom that comes from the multi-element space will allow exploration of whether multiple mechanisms can operate sequentially or simultaneously, which may yet lead to the creation of new alloys with a spectrum of mechanical properties that are significantly superior to those of current engineering alloys.

36 MATERIALS SCIENCE↗