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NASA NTRS2023

Superior Tensile Creep Behavior of A Novel Oxide Dispersion Strengthened Crconi Multi-Principal Element Alloy

The creep behavior of an additively manufactured (AM) yttrium oxide dispersion strengthened (ODS) CrCoNi multi-principal element alloy (MPEA) is investigated in this study. Tests were conducted over a constant tensile stress range of 40–200 MPa and a temperature range of 973–1173 K. A stress exponent of 6.5 ± 0.1 and activation energies in the range of 335–367 kJ/mol were measured. Compared to its non-ODS counterpart and its parent alloy (CrMnFeCoNi), AM ODS CrCoNi has superior creep resistance at all tested stresses and temperatures. The mechanism contributing to the excellent creep resistance of AM ODS CrCoNi is attributed to the interaction of mixed character dislocations with oxide particles. The creep ductility of AM ODS CrCoNi is higher than its nonODS counterpart due to a large percentage of low angle grain boundaries associated with its columnar grain structure. It was also found that creep ductility is significantly greater at the highest applied stress of 200 MPa compared to lower stresses. The steady state dislocation structure of AM ODS CrCoNi consists of long arrays of dislocations, which is different from that observed in non-ODS CrCoNi which consists of individual curved dislocations.

Seyed Gianmarco Sahragard-Monfared↗

NASA NTRSDate not supplied

Open-source Numerical Modeling of Solidification Cracking Susceptibility: Application to Refractory Alloy Systems

Introduction. Alloys such as aluminum, nickel-base, and austenitic stainless steels are susceptible to solidification cracking during welding and 3D printing. Compositional optimization is one method used to effectively mitigate solidification cracking of those alloy systems. With the surge in hypersonic and in-space propulsion activities, refractory metals (Nb, Mo, Ta, W, and Re) and their alloy derivatives are increasing in importance due to their extreme high melting point and retention of high-temperature strength; however, their chemistry was most typically optimized to promote ductility during mechanical operations such as drawing and forming. Welding of such alloys has been a challenge due to a number of issues including solidification cracking, atmospheric contamination (O, C, and N), as well as a shift in ductile-to-brittle transition to higher temperature following grain growth induced by welding. Compositional optimization of refractory alloys for solidification cracking resistance in particular is desirable as their usage increases with the advent of advanced manufacturing methods such as 3D printing. This work evaluates the effect of compositional variation in refractory metal systems on the solidification cracking susceptibility with the goals of optimizing existing alloys and joining process techniques, and formulating new alloys with increased solidification cracking resistance. Experimental Procedures. A python code was developed in a Jupyter notebook environment (Michael and Sowards, 2023) to facilitate the calculation of crack susceptibility index proposed by Kou (2015). Composition is entered as a single point, or as a 1-D or 2-D array. The notebook calls pycalphad (Otis and Liu, 2017 and Bocklund et al, 2020) to calculate the evolution of fraction solid as a function of temperature (under either Scheil or equilibrium assumptions) and then evaluates steepness of the fraction solid curve near the terminal stage of solidification to predict solidification cracking resistance. Open source thermodynamic databases available at online repositories are used (van de Walle). The process is setup in an automated fashion to generate plots that show variation in solidification cracking susceptibility according to composition on 1-D line plots or 2-D contour plots. The Jupyter notebook and crack susceptibility algorithm was also integrated with a widely used commercial CALPHAD code for validation and alloy exploration. Results and Discussion. The crack susceptibility model was first validated against a series of refractory alloy compositions evaluated in past work which utilized a specialized Varestraint test built inside a vacuum chamber environment (Lessman and Gold, 1971). The alloys tested in the Varestraint apparatus included T-111 (Ta-8W-2Hf), ASTAR-811C (Ta-8W-1Re-0.7Hf-0.025C), FS-85 (Nb-27Ta-10W-1Zr), T-222 (Ta-9.6W-2.4Hf-0.01C), Ta-10W, B-66 (Nb-5Mo-5V-1Zr), and SCb-291 (Nb-10W-10Ta). The initial test of the model showed a strong correlation with empirical Varestraint data, i.e., a Spearman rank correlation between model predictions and hot cracking measurements was observed to be greater than 0.8. Following the validation, a set of refractory metal binary mixtures was investigated to evaluate sensitivity of Nb, Mo, W, and Ta to C, N, and O content. A series of plots were produced that suggest ppmw ranges of C, N, and O where solidification cracking increases significantly and reaches a maximum. Also comparative ranking of each primary refractory metal to each interstitial was produced. For example C produces greater cracking response in Mo whereas O produces greater cracking response in Ta and Nb. Such compositional values have utility in setting limits on pickup of these interstitial elements during welding and printing rather than using a one-size-fits-all approach. Furthermore, the results have use in determining additive powder recycling requirements, which is especially pertinent for refractory metal powders due to their high cost compared to conventional alloys. Another application created thousands of hypothetical alloys within the nominal specified composition range of two widely used refractory alloys C103 (Nb-10Hf-1Ti) and TZM (Mo-0.5Ti-0.1Zr). The cracking index was calculated for the alloys and results were fed into machine learning regression techniques including Multiple Linear Regression, Ridge Regression, and Lasso Regression to determine relative potency each alloying element had on computed solidification cracking index. A series of linear equations were produced that relate composition of C103 and TZM to solidification cracking index. The crack susceptibility of C103 for example is described by an equation of the form: cracking index ~ O + 0.667*C + 0.635*N + 0.00037*Ta – 0.0008*Hf (in wt.%) From that equation, it is clear that O has strong propensity to induce solidification cracking. Interestingly, Hf is shown to reduce calculated cracking response. Finally, realizing the potential of this method to discover new refractory alloy formulations across the period table that have low solidification cracking sensitivity, the code was applied to new untested alloy systems including W-Zr-C, W-Ta-C, and others. Conclusions. In summary, an open source numerical method has been developed using Python code to calculate Kou’s crack susceptibility index. The method was applied to refractory metals which are inherently difficult to study from a weldability testing standpoint since inert shielding gas is not sufficient and welding is typically done in vacuum, especially in light of findings presented here where oxygen has profound influence on solidification cracking. This work revealed the effect of compositional variations on a series of refractory metals and showed the framework defined here will be useful in 1) the development of new alloys that have improved weldability and 3D printability, 2) placing compositional limits on existing alloys, and 3) ensuring adequate controls of manufacturing processes such as 3D printing where powder reuse is critical. Keywords. pycalphad; Python; refractory metals; solidification cracking. References. B. Bocklund et. al. (2020) http://doi.org/10.5281/zenodo.3630657. S. Kou. (2015) https://doi.org/10.1016/j.actamat.2015.01.034. G.G. Lessmann and R.E. Gold. Welding Journal, issue 1, pp. 1-s – 8-s (1971). F.N. Michael and J.W. Sowards. NASA/TM-20230002218 (2023). R. Otis and Z.-K. Liu. (2017) http://doi.org/10.5334/jors.140. A. Van de Wallle et. al. (2018) https://doi.org/10.1016/j.calphad.2018.04.003.

pycalphad↗

NASA NTRS2023

Short-Transverse Tensile Fracture Behavior of Thick AA2219 Plate - Effects of Theta (Al2Cu) Particle Size and Distribution

An investigation was conducted to obtain a better understanding on the microstructural characteristics of 5-inch-thick AA2219-T87 plate material and the mechanism that led to the unexpected low ductility in the short-transverse (ST) orientation. Materials characterization techniques were utilized to observe the microstructure of fractured tensile specimens and remnant plate material. The mechanism and cause of low ST ductility in the thick plate material is presented and discussed in this report.

Short-Transverse Orientation↗

NASA NTRS2024

Short-Term Elevated Temperature Mechanical Performance and Microstructure of A Niobium-Zirconium Alloy Produced via Laser Powder Bed Fusion In-Situ Alloying

Nb-1Zr is a readily fabricable, dispersion-strengthened niobium alloy with improved elevated temperature properties compared to commercially pure niobium. This low to moderate strength niobium alloy is desirable in thermal management systems for fission power and propulsion applications; however, pre-alloyed spherical feedstock for powder-based additive manufacturing processes is generally unavailable. Laser powder bed fusion (L-PBF) in-situ alloying of a Nb-1Zr chemistry was performed using a high-purity niobium feedstock coated with 1 wt% of zirconium-based ceramic compound nano-powders: ZrO 2 , ZrC, and ZrH 2 . The additively manufactured material was mechanically tested at elevated temperatures within a controlled environment in the as-built condition. For comparison, traditionally manufactured wrought feedstock was also tested within an identical environment. Examination of the materials’ microstructure and short-term elevated temperature mechanical response determined: in-situ alloying of spherical Nb powder feedstock with Zr-based ceramic nanoparticles can be successfully implemented; the ZrO 2 addition offered the greatest elevated temperature stability and strength but exhibited brittle behavior; the ZrC addition achieved a balance of room temperature ductility and elevated temperature strength; and the ZrH 2 -modified material had the lowest as-built interstitial content and showed high ductility with mechanical performance most similar to wrought Nb-1Zr.

Niobium Alloy↗

DOE OSTI2012

Elevated Temperature Primary Load Design Method Using Pseudo Elastic-Perfectly Plastic Model

A new primary load design method for elevated temperature service has been developed. Codification of the procedure in an ASME Boiler and Pressure Vessel Code, Section III Code Case is being pursued. The proposed primary load design method is intended to provide the same margins on creep rupture, yielding and creep deformation for a component or structure that are implicit in the allowable stress data. It provides a methodology that does not require stress classification and is also applicable to a full range of temperature above and below the creep regime. Use of elastic-perfectly plastic analysis based on allowable stress with corrections for constraint, steady state stress and creep ductility is described. This approach is intended to ensure that traditional primary stresses are the basis for design, taking into account ductility limits to stress re-distribution and multiaxial rupture criteria.

Carter, Peter↗

DOE OSTI2013

OBSERVATION AND MECHANISM OF HYDRIDE IN ZIRCALOY-4 AND LOCAL HYDRIDE RE-ORIENTATION INDUCED BY HIGH PRESSURE AT HIGH TEMPERATURES

Hydrided Zircaloy-4 samples were produced by a gas charging method to desired amounts of hydrogen. For low hydrogen content samples, the hydrided platelets appear elongated and needle-like, orientated in the circumferential direction. Mechanical testing was carried out by the ring compression method at various temperatures. Samples with higher hydrogen concentration resulted in lower strain before fracture and reduced maximum load. The trend between temperature and ductility was also very clear: increasing temperatures resulted in increased ductility of the hydrided cladding. A single through-wall crack was observed for a hydrided sample having very high hydrogen concentration under ring compression testing. For samples having lower hydrogen concentrations, the fracture surfaces traversed both circumferential and radial directions, and for which voids were observed near the hydrides. Mechanical tests to study hydride reorientation in these samples are under way, and the results will be reported in the near future.

Hydride↗

DOE OSTI2013

Rehabilitation of notch damaged steel beam using a carbon fiber reinforced multiphase-matrix composite

The retrofit of notch damaged steel beams is investigated via the experimental testing of nine wide-flange steel beam specimens and finite element simulation. Three notch configurations representing various damage levels were identified, and the beam specimens were retrofitted using CFRP laminates and a recently developed polymeric matrix composite - CarbonFlex - that exhibits superior energy dissipation and ductility properties, where the peak-load deflections were between 49.4% and 65.2% higher using the CarbonFlex-retrofitted beams. The results are attributed to the substantially higher damage tolerance capability of CarbonFlex than conventional CFRP. Finite element models were developed to investigate the damage processes and strain/ stress distributions near the notch tips. The numerical results match closely with the experimentally determined load-deflection curves and the strain fields obtained by the digital imaging correlations (DIC) system. Both experimental and numerical results clearly indicate the effectiveness of CarbonFlex, as a candidate retrofitting material, to retrofit damaged steel structures. Lastly, the micro-mechanisms by which CarbonFlex could sufficiently sustain a significant amount of the peak strength at large displacement ductility values are discussed with the aid of scanning electron microscopy (SEM) pictures.

Zhou, HongYu↗

DOE OSTI2013

A nanoscale duplex precipitation approach for improving the properties of Fe-base alloys

The precipitate size and number density are important factors for tailoring the mechanical behaviors of nanoscale precipitate-hardened alloys. However during thermal aging, the precipitate size and number density change leading to either poor strength or high strength but significantly reduced ductility. Here we demonstrate, by producing nanoprecipitates with unusual duplex structures in a composition-optimized multicomponent precipitation-hardened alloy, a unique approach to improve the stability of the alloy against the effects of thermal aging and consequently change in the mechanical properties. Our study provides compelling experimental evidence that these nanoscale precipitates consist of a duplex structures with a Cu-enriched bcc core that is partially encased by a B2-ordered Ni(Mn,Al) phase. This duplex structure enables the precipitate size and number density to be independently optimized, provides a more complex obstacle for dislocation movement due to the ordering and an additional interphase interface, and yields a high yield strength alloy without sacrificing the ductility.

Zhang, Zhongwu↗

DOE OSTI2014

Effects of Partial Phase Transformation on Characteristics of 9Cr Nanostructured Ferritic Alloy

The core structures of future nuclear systems require tolerance to extreme irradiation, and some critical components, for example, the fuel cladding in Sodium-cooled Fast Reactors (SFRs), have to maintain mechanical integrity to very high doses of 200 -400 dpa at high temperatures up to 700 degrees C. The high Cr nanostructured ferritic alloys (NFAs) are under intense research worldwide as a candidate core material. Although the NFAs have some admirable characteristics for high-temperature applications, their crack sensitivity is very high at high temperatures. The fracture toughness of high strength NFAs is unacceptably low above 300 degrees C. The objective of this study is to develop processes and microstructures with improved high temperature fracture toughness and ductility. To optimize the afterextrusion heat treatment condition, both the computational simulation technique on phase equilibrium and the basic microstructural and mechanical characterization have been carried out. 9 Cr-NFA was produced by the mechanical alloying of pre-alloyed Fe-9Cr base metallic powder and yttria particles, and subsequent extrusion. The post-extrusion heat-treatments of various conditions were applied to the asextruded NFA. The tensile and fracture toughness tests were conducted for as-extruded and heat-treated samples at up to 700 degrees C. Fracture toughness of the NFA has increased by more than 40% at every testing temperature after heat-treatment in the inter-critical temperature range. The increment of fracture toughness of the NFA after post-extrusion heat-treatment is attributed to the increased strength at below 500 degrees C, and an increased ductility at 700 degrees C.

Ji Hyun, Yoon↗

DOE OSTI2017

Development of Bulk Nanocrystalline Tungsten Alloys for Fusion Reactor Structures

This project developed a technology for manufacturing bulk ultrafine tungsten materials that are at or near full density for fusion reactor structural applications, aiming to improve ductility and toughness of tungsten before and after irradiation. The project involved the development of fabrication processes for making bulk ultrafine grained W, the development of new alloys of ultrafine grained W and evaluations of properties of these specific materials. The goal of this fabrication process is to produce fully dense bulk W with ultrafine grain sizes, with uniform distributions of grain size and additives. To date there is no known process that could be used to make ultrafine grained tungsten in a fully dense state and in a cost-acceptable fashion. The specific technology described in this proposal for making ultrafine grained tungsten involves a suite of nano-particle processing and sintering techniques. The program also developed new alloys of ultrafine grained W, e.g. W-(Ta,V,Ti)-TiC alloys to improve ductility and toughness before and after irradiation. By completing this project, we achieved the following objectives: • Demonstrated experimentally the feasibility of producing bulk ultrafine grained tungsten alloys (at or near 100% dense, <1000 nm grain size) using the proposed process • Demonstrated the proposed ultrafine grained W alloys, namely, W-(Ta, V, Ti)-TiC, can indeed be made using the proposed process • Demonstrated that the properties of nano tungsten alloys meet the requirements for fusion reactor applications. The overall goal was to harness the potential of ultrafine grained W produced using the proposed processes as the core structural materials for future fusion reactors. The project was very successful overall, meeting all milestones and surpassing project goals in terms of process development and material’s blistering resistance properties. A novel process similar to the conventional press-and-sinter powder metallurgy method was developed for producing ultrafine grain tungsten from nanosize tungsten powders. Grain growth was significantly controlled during sintering by certain alloy compositions, particularly Ti, and most compositions sintered to maximum densification. To optimize this process, the effect of processing parameters on the densification and grain growth of nano-W powders was investigated. Near-fully densified tungsten was obtained at sintering temperatures between 1100 and 1300 °C, and both Ar and H2 sintering atmospheres were investigated. The Ar sintering atmosphere was determined to more favorably promote densification and minimize grain growth. The nanosized tungsten powder compacts were subjected to reduction in H2 as a part of the sintering cycle. The reduction temperature was found to have significant effects on the sintering of nano-W powder, primarily as a result of grain coarsening, which was seen at temperatures as low as 700 °C. In an effort to inhibit grain growth, the effect of Ti-based additives on the densification and grain growth of nano-W powders was investigated in this project. The addition of 1 wt.% Ti into tungsten led to more than a 63% decrease in average grain size of sintered samples at comparable density levels. Compared to conventional high temperature sintering, a lower temperature sintering cycle for a longer hold time resulted in both near-full density and fine grain size. The roles of the Ti additives include not only the inhibition of grain growth, but also the potential absorption of oxygen from W particles. The project has resulted in the publication; thus far, of six peer reviewed journal articles and seven conference presentations, as well as a master’s thesis. Two additional journal articles are currently in preparation. Presentations and articles were a particular focus of the second half of the project, once significant experimentation had been performed and analyzed. As part of our efforts to disseminate information of our results, the W research teams with Prof. Fang had a strong presence at multiple international conferences during 2015 and 2016. Several research groups in the US are now performing experiments using the ultrafine grained W materials.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2017

Application of a Novel DCPD Adjustment Method for the J-R Curve Characterization: A study based on ORNL and ASTM Interlaboratory Results

Material fracture toughness in the fully ductile region can be described by a J-integral vs. crack growth resistance curve (J-R curve). As a conventional J-R curve measurement method, the elastic unloading compliance (EUC) method becomes impractical for elevated temperature testing due to relaxation of the material and friction induced back-up shape of the J-R curve. One alternative solution of J-R curve testing applies the Direct Current Potential Drop (DCPD) technique for measuring crack extension. However, besides crack growth, potential drop can also be influenced by plastic deformation, crack tip blunting, etc., and uncertainties exist in the current DCPD methodology especially in differentiating potential drop due to stable crack growth and due to material deformation. Thus, using DCPD for J-R curve determination remains a challenging task. In this study, a new adjustment procedure for applying DCPD to derive the J-R curve has been developed for conventional fracture toughness specimens, including compact tension, three-point bend, and disk-shaped compact specimens. Data analysis has been performed on Oak Ridge National Laboratory (ORNL) and American Society for Testing and Materials (ASTM) interlaboratory results covering different specimen thicknesses, test temperatures, and materials, to evaluate the applicability of the new DCPD adjustment procedure for J-R curve characterization. After applying the newly-developed procedure, direct comparison between the DCPD method and the normalization method on the same specimens indicated close agreement for the overall J-R curves, as well as the provisional values of fracture toughness near the onset of ductile crack extension, Jq, and of tearing modulus.

DCPD↗

DOE OSTI2017

3D Microstructures for Materials and Damage Models

Many challenges exist with regard to understanding and representing complex physical processes involved with ductile damage and failure in polycrystalline metallic materials. Currently, the ability to accurately predict the macroscale ductile damage and failure response of metallic materials is lacking. Research at Los Alamos National Laboratory (LANL) is aimed at building a coupled experimental and computational methodology that supports the development of predictive damage capabilities by: capturing real distributions of microstructural features from real material and implementing them as digitally generated microstructures in damage model development; and, distilling structure-property information to link microstructural details to damage evolution under a multitude of loading states.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Quenching and Partitioning Process Development to Replace Hot Stamping of High Strength Automotive Steel

The present project investigated Quenching and Partitioning (Q&P) to process cold rolled steels to develop high strength sheet steels that exhibit superior ductility compared to available grades with the intent to allow forming of high strength parts at room temperature to provide an alternative to hot stamping of parts. Hot stamping of boron alloyed steel is the current technology to manufacture thinner gauge sections in automotive structures to guarantee anti-intrusion during collisions whilst improving fuel efficiency by decreasing vehicle weight. Hot stamping involves reheating steel to 900 °C or higher followed by deformation and quenching in the die to produce ultra-high strength materials. Hot stamping requires significant energy to reheat the steel and is less productive than traditional room temperature stamping operations. Stamping at elevated temperature was developed due to the lack of available steels with strength levels of interest possessing sufficient ductility enabling traditional room temperature forming. This process is seeing growing demand within the automotive industry and, given the reheating step in this operation, increased energy consumption during part manufacturing results. The present research program focused on the development of steel grades via Q&P processing that exhibit high strength and formability enabling room temperature forming to replace hot stamping. The main project objective consisted of developing sheet steels exhibiting minimum ultimate tensile strength levels of 1200 MPa in combination with minimum tensile elongation levels of 15 pct using Q&P processing through judicious alloy design and heat treating parameter definition. In addition, detailed microstructural characterization and study of properties, processing and microstructure interrelationships were pursued to develop strategies to further enhance tensile properties. In order to accomplish these objectives, alloy design was conducted towards achieving the target properties. Twelve alloys were designed and laboratory produced involving melting, alloying, casting, hot rolling, and cold rolling to obtain sheet steels of approximately 1 mm thickness. Q&P processing of the samples was then conducted. Target properties were achieved and substantially exceeded demonstrating success in the developed and employed alloy design approaches. The best combinations of tensile properties were found at approximately 1550 MPa with a total elongation in excess of 20 pct clearly showing the potential for replacement of hot stamping to produce advanced high strength steels.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Casings for use in a system for fracturing rock within a bore

In disclosed explosive units for use in a wellbore, the casing can include a tubular outer body comprising grooves, pockets, or other variances in thickness that create stress concentrations that promote shear and tensile fragmentation instead of ductile expansion of the casing, which can negatively impact permeability of a wellbore. In other embodiments, the casing can comprise non-ductile and/or reactive material which responds to explosive or high temperature loading by brittle failure, disintegration, melting, burning, and/or chemically reacting with the energetic materials and/or the borehole environment. Such embodiments can enhance the permeability of the wellbore after detonation.

03 NATURAL GAS↗

DOE OSTI2018

Super Hot EGS and the Newberry Deep Drilling Project

A productive geothermal well drilled into super-hot rock (SHR) with a temperature above 400°C will produce super-critical fluid. At a flow rate of 60 kg/s, a SHR well could produce 50 MWe compared to 5-7 MWe for the same flow at 200°C. Even though these deeper, super-hot wells will cost more, the high energy density means power produced by engineered geothermal systems (EGS) can meet the market ($46 MW-hr) by directly tapping the heat source. We propose a proof of concept where hot rock is close to the surface (~5 km), and the cost of drilling and EGS stimulation will be lowest. A suitable, ready-to-go SHR site is on Newberry Volcano, Oregon, one of the largest geothermal heat reservoirs in the USA, extensively studied for the last 40 years. Millions of dollars have already been invested in the site by private geothermal developers and the US Department of Energy (DOE), resulting in a ready-to-use facility with the necessary infrastructure, environmental permits, land commitments, and monitoring plans. The Newberry Deep Drilling Project (NDDP) will be located at an idle geothermal exploration well, NWG 46-16, drilled in 2008, 3500 m deep and 320°C at bottom, which will be deepened another 1000 to 1300 m to reach 500 °C. The original well was drilled with few lost circulation zones and the temperature profile indicates conductive heat flow. Compared to other SHR projects world-wide, this well would return more materials (cuttings, core and fluids) with more predictable drilling conditions, thus providing a suite of data near and across the brittle-ductile transition in silicarich rocks. After drilling, a hydraulic well stimulation will both change the pore pressure in fractures and cool the fracture walls resulting in permeability enhancement through both thermal fracturing, and hydro-shearing. The first step for the NDDP was an International Continental Drilling Program (ICDP) sponsored workshop held at the OSU-Cascades campus in Bend from Sept. 10-14, 2017. The workshop concluded by setting ambitious goals for NDDP: 1) test EGS above the critical point of water, 2) collect samples of rocks within the brittle-ductile transition, 3) investigate volcanic hazards, 4) study magmatic geomechanics, 5) calibrate geophysical imaging techniques, and 6) test technology for drilling, well completion, and geophysical monitoring in a very high temperature environment. The second step, completed January 15, 2018, was submitting a proposal to ICDP for 46-16 deepening. The next steps will be to continue building a team with project, technology, and investment partners to make NDDP a reality.

EGS, Geothermal, Newberry↗

DOE OSTI2023

Methods of modifying material flow mode during machining and products formed thereby

Methods of inducing segmented flow in a material in which a ductile flow mode would otherwise occur during machining. A monolayer molecular film is formed on a surface of a body of a material in a state such that the material exhibits ductile flow when subjected to shear. The monolayer molecular film has molecules each having a head group adsorbed to the surface, a terminal group, and a hydrocarbon chain therebetween having a chain length of greater than 6. A surface portion of the body is removed by engaging the body with a tool in a contact region below the surface of the body and moving the tool relative to the body to remove the surface portion and the monolayer molecular film thereon. The monolayer molecular film induces segmented flow in the material during the removing of the surface portion.

Sugihara, Tatsuya↗

DOE OSTI2023

High conductivity magnesium alloy

A castable, moldable, or extrudable magnesium-based alloy that includes one or more insoluble additives. The insoluble additives can be used to enhance the mechanical properties of the structure, such as ductility and/or tensile strength. The final structure can be enhanced by heat treatment, as well as deformation processing such as extrusion, forging, or rolling, to further improve the strength of the final structure as compared to the non-enhanced structure. The magnesium-based composite has improved thermal and mechanical properties by the modification of grain boundary properties through the addition of insoluble nanoparticles to the magnesium alloys. The magnesium-based composite can have a thermal conductivity that is greater than 180 W/m-K, and/or ductility exceeding 15-20% elongation to failure.

Sherman, Andrew J.↗

DOE OSTI2023

High conductivity magnesium alloy

Sherman, Andrew J.↗