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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 1,333 records · Page 74
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Hydraulic Properties of Grout Monoliths Containing Organic Ion Exchange Resin - 18369

The Waste Treatment and Immobilization Plant (WTP) at Hanford is being constructed to treat 56 million gallons of radioactive waste currently stored in underground tanks at the Hanford site. Operation of the WTP will generate several solid secondary waste (SSW) streams including spent spherical resorcinol formaldehyde cation exchange resin (IXr). The current plan for safe disposal of IXr is solidification in cementitious material (CM) typically comprised of cement, fly ash and blast furnace slag. Three CM formulations were tested to stabilize IXr for long-term land disposal. Two IXr loading rates, 0.1 and 0.3 v/v IXr:grout were used with the three CM formulations to prepare simulated waste form monoliths for hydraulic property testing. Following curing, the monoliths were removed from molds and tested to determine saturated hydraulic conductivity (K{sub sat}) and water retention properties. K{sub sat} was measured using a standard flexible permeameter method ASTM D-5084-10. A constant vapor pressure (CVP) method was used to determine van Genuchten parameters for desorption moisture retention curves for each of the SSW grout formulations. For the CVP method, vacuum saturated, intact wafers approximately 1.25 cm thick were placed above a saturated salt solution inside a sealed container for equilibration. Each saturated salt solution has an associated vapor pressure related to relative humidity in the container. Visual examination and three-dimensional x-ray micro computed tomography (μCT) indicated that the IXr was uniformly distributed in the cured waste form. Saturated hydraulic conductivity was within the range previously reported by Flach et al. in a study of the hydraulic properties of 98 pastes and grouts. The solidification of IXr in CM resulted in a waste form with water retention properties similar to cementitious pastes. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2019

Study on Application of Geopolymer to the Retrieval of Fuel Debris in Fukushima Dai-ichi NPP

In order to retrieve fuel debris in Fukushima Dai-ichi NPP, many retrieval methods are proposed. Geopolymer is the candidate material applied for an alternative retrieval method. In this concept, Geopolymer can be used to stabilize fuel debris and suppress the diffusion of radioactive materials. Objective: Evaluation of geopolymer applied for retrieving fuel debris. Slump Flow Test: Slump flow values decreased as the test temperature increased. In air condition, water molecules evaporated from geopolymer and the viscosity of geopolymer increased. In water condition, the same trends as in air condition were observed. Slump flow values of geopolymer also depended on the elapsed time after mixing. By adding water, the slump flow values of geopolymer became higher (Even at 80 deg. C). It is possible to adjust the solidification time (Setting time) of geopolymer. Solidification Process of Geopolymer: After the first layer solidified, the second layer was injected. At 300 deg. C, porous structure was observed in the first layer, while the second layer structure was intact. In the actual application, multilayered geopolymer may be used to stabilize fuel debris. Conclusion: Fluidity of geopolymer decreased with raising temperature. Setting time can be adjusted by adding water. Geopolymer may be applied by injecting multiple times on high temperature materials above 100 deg. C.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2016

Impact of gravity on hydrate saturation in gas‐rich environments

Abstract We extend a one‐dimensional analytical solution by including buoyancy‐driven flow to explore the impact of gravity on hydrate formation from gas injection into brine‐saturated sediments within the hydrate stability zone. This solution includes the fully coupled gas and liquid phase flow and the associated advective transport in a homogeneous system. We obtain the saturations assuming Darcy flow under combined pressure and gravity gradients; capillary forces are neglected. At a high gas supply rate, the overpressure gradient (gradient of water pressure deviation from the hydrostatic pressure) dominates the gas flow, and the hydrate saturation is independent of the flow rate and flow direction. At a low gas supply rate, the buoyancy (the drive for gas flow induced by the density difference between gas and liquid) dominates the gas flow, and the hydrate saturation depends on the flow rate and flow direction. Hydrate saturation is highest for upward flow, and lowest for downward flow. Hydrate saturation decreases with flow rate for upward flow, and increases with flow rate for downward flow. In all cases, hydrate saturation is constant behind the hydrate solidification front. Gas saturation is homogeneous and close to the residual value for upward flow at a low rate; gas flows at the rate it is supplied. Gas saturation is much greater than the residual value, and decreases from the gas inlet to the hydrate solidification front for downward flow at a very low rate. The effect of gravity is usually negligible in laboratory experiments, yet is significant in natural hydrate systems.

You, Kehua↗
DOE OSTI2019

Bismuth-Based Perovskite-Inspired Solar Cells: In Situ Diagnostics Reveal Similarities and Differences in the Film Formation of Bismuth- and Lead-Based Films

Organic–inorganic lead-based halide perovskite compounds currently yield thin film solar cells with a power conversion efficiency (PCE) of >23%. However, replacing the lead with less-toxic elements while maintaining a high PCE remains a challenge. For this reason, there has been significant effort to develop Pb-free compounds, including methylammonium bismuth iodide (MA 3 Bi 2 I 9 ), but such systems severely underperform when compared with the prototypical Pb-based methylammonium lead iodide (MAPbI 3 ). For the latter, it is known that lead complexes with polar solvents, such as dimethyl sulfoxide (DMSO) and dimethylformamide (DMF), to form iodoplumbates which can co-crystallize into solvated phases. Herein, the solidification and growth behaviors of Bi- and Pb-based films is investigated using multi-probe in situ characterization methods. It is shown that the Bi-based compound crystallizes directly and rapidly into a textured polycrystalline microstructure from a precursor solution without evolving through intermediate crystalline solvated phases, in contrast to MAPbI 3 . This solidification process produces isolated crystals and challenges the growth of continuous and crystalline films required for solar cells. Further, it is revealed that solvent engineering with antisolvent dripping is crucial to enable the formation of continuous polycrystalline films of MA 3 Bi 2 I 9 and functional solar cells thereof.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Microstructural development in DED stainless steels: applying welding models to elucidate the impact of processing and alloy composition

Austenitic stainless steel microstructures produced by directed energy deposition (DED)are analogous to those developed during welding, particularly high energy density welding. To better understand microstructural development during DED, theories of microstructural evolution,which have been established to contextualize weld microstructures, are applied in this study to microstructural development in DED austenitic stainless steels. Phenomenological welding models that describe the development of oxide inclusions, compositional microsegregation, ferrite,matrix austenite grains, and dislocation substructures are utilized to clarify microstructural evolution during deposition of austenitic stainless steels. Two different alloys, 304L and 316L, arecompared to demonstrate the broad applicability of this framework for understanding microstmctural development during the DED process. Despite differences in grain morphology and solidification mode for these two alloys (which can be attributed to compositional differences),similar tensile properties are achieved. It is the fine-scale compositional segregation and dislocation structures that ultimately determine the strength of these materials. The evolution of microsegregation and dislocation structures is shown to be dependent on the rapid solidification and thermomechanical history of the DED processing method and not the composition of the starting material.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Production of monodisperse cerium oxide microspheres with diameters near 100 µm by internal-gelation sol–gel methods

Cerium dioxide microspheres with uniform diameters between 65 – 211 µm were fabricated using internal gelation sol-gel methods. Although uniform microspheres are produced for nuclear fuel applications with diameters above 300 µm, sol-gel microspheres with diameters of 50 - 200 µm have historically been made by emulsion techniques and had poor size uniformity [1, 2]. An internal gelation, sol-gel apparatus was designed and constructed to accommodate the production of small, uniform microspheres whereby cerium-containing solutions were dispersed into flowing silicone oil and heated in a gelation column to initiate solidification [3, 4]. Problems with premature feed gelation and microsphere coalescence were overcome by equipment modifications unique among known internal gelation setups. Microspheres were fabricated and sized in batches as a function of dispersing needle diameter and silicone oil flow rate in the two-fluid nozzle in order to determine the range of sizes possible and corresponding degree of monodispersity. Initial experiments with poor size uniformity were linked to microsphere coalescence in the gelation column prior to solidification as well as excessive flow rates for the cerium feed solution. Average diameter standard deviations as low as 2.23% were observed after optimization of flow rates and minimization of coalescence reactions.

cerium oxide↗
DOE OSTI2017

Comparative evaluation of cast aluminum alloys for automotive cylinder heads: Part I Microstructure evolution

The present study stages a comparative evaluation of microstructure and associated mechanical and thermal response for common cast aluminum alloys that are used for manufacturing automotive cylinder heads. The systems considered are Al-Cu (206-T6), Al-Si-Cu (319-T7), and Al-Si (356-T6, A356-T6, and A356 + 0.5Cu-T6). The focus of the present manuscript is on the evaluation of microstructure at various length scales after aging, while the second manuscript will deal with the mechanical and thermal response of these alloys due to short-term (aging) and long-term (pre-conditioning) heat treatments. At the grain-scale, the Al-Cu alloy possessed an equiaxed microstructure as opposed to the dendritic structure for the Al-Si-Cu or Al-Si alloys which is related to the individual solidification conditions for these alloy systems. The composition and morphology of intermetallic precipitates within the grain and at the grain/dendritic boundary are dictated by the alloy chemistry, solidification, and heat treatment conditions. At the nanoscale, these alloys contain various metastable strengthening precipitates (GPI and θ''θ'' in Al-Cu alloy, θ'θ' in Al-Si-Cu alloy, and β'β' in Al-Si alloys) with varying size, morphology, coherency, and thermal stability.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Microstructure Development of 308L Stainless Steel During Additive Manufacturing

$In$ $situ$ high-energy X-ray diffraction measurements were completed during deposition of 308L stainless steel wire onto a 304L stainless steel substrate. Attempts were made to extract microstructural features such as phase fraction and internal stress, as well as temperature evolution immediately following the deposition. The limited data that could be collected during deposition and rapid solidification are critically examined. High-energy X-rays coupled with relatively slow detectors were utilized to enable determination of orientation-dependent lattice parameters accurately enough to comment on phase strain evolution between austenite and ferrite. Here, information about the hydrostatic and deviatoric stress states of the constituent phases was determined on time scales that are relevant to their development. However, the time resolution of the technique was insufficient to monitor phase evolution during the solid–solid phase transformation and, more so, during solidification. Moreover, the accurate and absolute determination of inherently statistical parameters, such as phase fraction, depends critically on the ability to sample a statistically significant numbers of grains in the microstructure.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Thermodynamics and Kinetics of Refractory Multi-principal Element Alloys: An Experimental and Modeling Comparison

Here, the search for structural alloys capable of ultrahigh temperature performance has led to the exploration of refractory multi-principal element alloys (RMPEAs). In this work, experimental results for solidification segregation and homogenization of two RMPEAs, NbTaTiW and MoNbTaTi, are compared to simulations using the Scheil and DICTRA modules in Thermo-Calc®. Scheil calculations accurately predict the observed solidification segregation, while DICTRA predicts general trends and can provide a minimum time to achieve homogenization at a given temperature.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Oxygen Effects and Selective Oxidation of Group IV Alloying Additions in Group V-Based Refractory Multi-principal Element Alloys

Refractory multi-principal element alloys (RMPEAs) hold significant potential for advancing ultra-high-temperature technologies due to their remarkable strength retention under these conditions. However, the beneficial effects of alloying on microstructural evolution and mechanical properties are often obscured by the presence of interstitial alloying elements. The intricate interactions between substitutional alloying elements of Groups IV, V, and VI and interstitial content, whether intentional or incidental, remain poorly understood. In this study, we investigate the impact of dissolved oxygen on the microstructural evolution and stability of RMPEAs primarily composed of Group V elements, Nb and V, along with Group IV elements Ti, Zr, and Hf. We show that the strong affinity of oxygen for Group IV elements Zr and Hf leads to the internal precipitation of oxides during heat treatment, which competes with the homogenization of the as-cast dendritic microstructure. Here, we demonstrate that careful control and design of oxygen content and Group IV alloying additions are essential to minimize micro-segregation and prevent the detrimental precipitation of internal oxides. To address these challenges, we propose employing non-equilibrium solidification calculations to predict and optimize as-cast solidification structures, thereby reducing the reliance on homogenization processes.

Alloy design↗
DOE OSTI2013

Arc distribution during the vacuum arc remelting of Ti-6Al-4V

Currently, the temporal distribution of electric arcs across the ingot during vacuum arc remelting (VAR) is not a known or monitored process parameter. Previous studies indicate that the distribution of arcs can be neither diffuse nor axisymmetric about the center of the furnace. Correct accounting for the heat flux, electric current flux, and mass flux into the ingot is critical to achieving realistic solidification models of the VAR process. The National Energy Technology Laboratory has developed an arc position measurement system capable of locating arcs and determining the arc distribution within an industrial VAR furnace. The system is based on noninvasive magnetic field measurements and a VAR specific form of the Biot–Savart law. The system was installed on a coaxial industrial VAR furnace at ATI Albany Operations in Albany, OR. This article reports on the different arc distributions observed during production of Ti-6Al-4V. It is shown that several characteristic arc distribution modes can develop. This behavior is not apparent in the existing signals used to control the furnace, indicating the measurement system is providing new information. It is also shown that the different arc distribution modes observed may impact local solidification times, particularly at the side wall.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Modeling of Dendritic Evolution of Continuously Cast Steel Billet with Cellular Automaton

In order to predict the dendritic evolution during the continuous steel casting process, a simple mechanism to connect the heat transfer at the macroscopic scale and the dendritic growth at the microscopic scale was proposed in the present work. As the core of the across-scale simulation, a two-dimensional cell automaton (CA) model with a decentered square algorithm was developed and parallelized. Apart from nucleation undercooling and probability, a temperature gradient was introduced to deal with the columnar-to-equiaxed transition (CET) by considering its variation during continuous casting. Based on the thermal history, the dendritic evolution in a 4 mm × 40 mm region near the centerline of a SWRH82B steel billet was predicted. The influences of the secondary cooling intensity, superheat, and casting speed on the dendritic structure of the billet were investigated in detail. The results show that the predicted equiaxed dendritic solidification of Fe-5.3Si alloy and columnar dendritic solidification of Fe-0.45C alloy are consistent with in situ experimental results [Yasuda et al. Int J Cast Metals Res 22:15–21 (2009); Yasuda et al. ISIJ Int 51:402–408 (2011)]. Moreover, the predicted dendritic arm spacing and CET location agree well with the actual results in the billet. The primary dendrite arm spacing of columnar dendrites decreases with increasing secondary cooling intensity, or decreasing superheat and casting speed. Meanwhile, the CET is promoted as the secondary cooling intensity and superheat decrease. However, the CET is not influenced by the casting speed, owing to the adjusting of the flow rate of secondary spray water. Compared with the superheat and casting speed, the secondary cooling intensity can influence the cooling rate and temperature gradient in deeper locations, and accordingly exerts a more significant influence on the equiaxed dendritic structure.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Evaluation of the Microstructure and Performance of Fe-21Cr-15Ni-6Mn-Nb Nonmagnetic Stainless Steel Welded Joints

In the present study, double-sided gas shield welding (GSW), in a single pass, was applied to Fe-21Cr-15Ni-6Mn-Nb nonmagnetic stainless steel plate. The microstructure and performance of the welded joint were investigated via microstructural and phase analysis, mechanical testing and magnetic analysis. The results showed a satisfactory micrographic appearance with full penetration, and no solidification defects observed in the welded joint, which showed typical epitaxial growth characteristics in the welding solidification. Slight grain growth, with an average size of ~ 18.9 μm, occurred in the heat-affected zone (HAZ). The primary dendrite arms, on both sides of welding joint, grew along the direction of the temperature gradient and met at the centerline of the weld with no parting microstructure in evidence. The secondary dendrite arm spacing was stable in all parts of the weld zone (WZ). The hardness of the weld zone was higher than that of the HAZ and the base metal (BM), with the lowest hardness occurring in the HAZ. The results of tensile testing showed a higher strength of the welded metal (WM) compared to the BM, and a good strength-ductility balance of the welded joint. The impact energy of the HAZ was higher than that of the WZ, corresponding to 60.5 J at room temperature and 52.7 J at − 196 °C. Microvoid coalescence, concurrent with crack propagation along the direction of the long axis of the dendritic sub-grains, was observed during plastic deformation in the WZ. Additionally, the excellent paramagnetic characteristics of the welded specimens were revealed.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Process-Structure-Property Relationships for 316L Stainless Steel Fabricated by Additive Manufacturing and Its Implication for Component Engineering

We investigate the process-structure-property relationships for 316L stainless steel prototyping utilizing 3-D laser engineered net shaping (LENS), a commercial direct energy deposition additive manufacturing process. Our study concluded that the resultant physical metallurgy of 3-D LENS 316L prototypes is dictated by the interactive metallurgical reactions, during instantaneous powder feeding/melting, molten metal flow and liquid metal solidification. This study also showed 3-D LENS manufacturing is capable of building high strength and ductile 316L prototypes due to its fine cellular spacing from fast solidification cooling, and the well-fused epitaxial interfaces at metal flow trails and interpass boundaries. However, without further LENS process control and optimization, the deposits are vulnerable to localized hardness variation attributed to heterogeneous microstructure, i.e., the interpass heat-affected zone (HAZ) from repetitive thermal heating during successive layer depositions. Most significantly, the current deposits exhibit anisotropic tensile behavior, i.e., lower strain and/or premature interpass delamination parallel to build direction (axial). This anisotropic behavior is attributed to the presence of interpass HAZ, which coexists with flying feedstock inclusions and porosity from incomplete molten metal fusion. Our current observations and findings contribute to the scientific basis for future process control and optimization necessary for material property control and defect mitigation.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Anomalous Annealing Response of Directed Energy Deposited Type 304L Austenitic Stainless Steel

Directed energy deposited (DED) and forged austenitic stainless steels possess dissimilar microstructures but can exhibit similar mechanical properties. In this study, annealing was used to evolve the microstructure of both conventional wrought and DED type 304L austenitic stainless steels, and significant differences were observed. In particular, the density of geometrically necessary dislocations and hardness were used to probe the evolution of the microstructure and properties. Forged type 304L exhibited the expected decrease in measured dislocation density and hardness as a function of annealing temperature. Here, the more complex microstructure–property relationship observed in the DED type 304L material is attributed to compositional heterogeneities in the solidification microstructure.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Ageless Aluminum-Cerium-Based Alloys in High-Volume Die Casting for Improved Energy Efficiency

Strong chemical reactions between Al and Ce lead to the formation of intermetallics with exceptional thermal stability. The rapid formation of intermetallics directly from the liquid phase during solidification of Al-Ce alloys leads to an ultrafine microconstituent structure that effectively strengthens as-cast alloys without further microstructural optimization via thermal processing. Die casting is a high-volume manufacturing technology that accounts for greater than 40% of all cast Al products, whereas Ce is highly overproduced as a waste product of other rare earth element (REE) mining. Reducing heat treatments would stimulate significant improvements in manufacturing energy efficiency, exceeding (megatonnes/year) per large-scale heat-treatment line. In this study, multiple compositions were evaluated with wedge mold castings to test the sensitivity of alloys to the variable solidification rate inherent in high-pressure die casting. Once a suitable composition was determined, it was successfully demonstrated at 800 lbs/h in a 600-ton die caster, after which the as-die cast parts performed similarly to ubiquitous A380 in the same geometry without requiring heat treatment. Furthermore, this work demonstrates the compatibility of Al REE alloys with high-volume die-casting applications with minimal heat treatments.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Laser spot welding of additive manufactured 304L stainless steel

Here, the goal of this work is to understand if an additively manufactured 304L stainless steel exhibits similar spot-welding behavior as wrought 304L stainless steel. Due to the many differences between an additively manufactured component and wrought product, it is important to determine how the material interacts with the laser and how it affects the weld bead morphology. In this paper, the laser coupling efficiency, weld size, and solidification of spot welds produced in wrought and additively manufactured 304L stainless steel were investigated. The coupling efficiency of wrought and additively manufactured 304L stainless steel of similar surface condition were approximately the same over a range of applied laser energies. Laser welding of the untreated (rougher) surface of additively manufactured 304L, however, showed improved coupling efficiency ranging between 3.3 and 100%. The rougher surface traps the incoming light and increases the coupling efficiency at lower laser energies, while at higher energy, the absorption efficiency is dominated by intrinsic absorption from the keyhole formation rather than surface roughness. The resulting spot weld microstructures differed from welds made in wrought 304L and additively manufactured 304L. Welds made in wrought 304L were fully austenitic containing what is suspected to be massive austenite, which suggests that these welds solidified as primary ferrite. Welds made in additively manufactured 304L were also fully austenitic and contained both cellular austenite and what is suspected to be massive austenite. These observations mean that welds made in additively manufactured 304L solidified as primary ferrite and primary austenite. The differences in weld microstructures made in wrought and AM 304L can be attributed to differences in the composition and solidification rate.

304L stainless steel↗
DOE OSTI2018

Strengthening mechanisms in directed energy deposited austenitic stainless steel

Microstructures and mechanical properties are evaluated in austenitic stainless steel structures fabricated by directed energy deposition (DED) considering the effects of applied loading orientation, build geometry, and distance from the deposition baseplate. Locations within an as-deposited build with different thermomechanical history display different yield strength, while those locations with similar history have approximately the same yield strength, regardless of test specimen orientation. Thermal expansion of deposited material near the baseplate is inhibited by the mechanical constraint imposed by the baseplate, promoting plastic deformation and producing a high density of dislocations. Concurrently, high initial cooling rates decrease away from the baseplate as the build is heated, causing an increased spacing of cellular solidification features. An analysis of strengthening mechanisms quantitatively established for the first time the important strengthening contribution of high dislocation densities in the materials (166–191 MPa) to yield strength that ranged from 438 to 553 MPa in the present DED fabricated structures. A newly adopted mechanistic relationship for microsegregation strengthening from the literature indicated an additional important contribution to strengthening (123–135 MPa) due to the cellular solidification features. These findings are corroborated by the measured evolution of microstructure and hardness caused by annealing the DED material. Finally, these results suggest that the mechanical properties of deposited austenitic stainless steels can be influenced by controlling thermomechanical history during the manufacturing process to alter the character of compositional microsegregation and the amount of induced plastic deformation.

36 MATERIALS SCIENCE↗