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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

ASTM International Conference on Additive Manufacturing – 2022

The In-Situ Project: Correlating In-situ monitoring data and Non-Destructive Evaluation (NDE) methods to characterize defect populations in Laser Powder Bed Fusion (L-PBF) material NDE is critical to enable the safe use of additive manufactured (AM) parts in aerospace applications. However, traditional NDE methods are not fully adaptable to complex AM geometries to appropriately screen for critical defects, and L-PBF processes inherently generate defects. In-situ monitoring techniques can give information about the quality of the build process and indicate process variations that could potentially create defects. Proven, causal correlations between in-situ monitoring indications and resulting defects are needed to inform about the final quality of the part. Thus, the development of a new approach is necessary. NASA started a two-phase study that would investigate techniques for characterizing defect populations in L-PBF material, first in material with induced defects, then in a nominal L-PBF process, by correlating in-situ, NDE, and serial sectioning data. Objectives also include the evaluation of seeded defect methodologies for realistic defect creation, creating a baseline of defect populations in a Qualified Material Process (QMP), characterizing the effect of heat treatment, and correlating defect populations with tensile and fatigue properties. By comparing computed tomography images, in-situ monitoring images, and metallography images, the team has been able to draw preliminary conclusions. They include a better understanding of the limitation of the NDE tools, learning about the “healing” of the samples observed during layer building and a comparison study on different laser power variation samples. Those preliminary conclusions will help dictate the follow-up work that will be presented at the conference.

additive manufacturing↗
DOE OSTI2021

A short review of defect superlattice formation in metals and alloys under irradiation

Irradiation damage drives complex and coupled phenomena in materials at far-from-equilibrium conditions. The self-organization of nanoscale defects in materials under irradiation shows great potential to tailor the physical properties of materials by controlling nanopatterned microstructures. Irradiation-induced gas bubble and void superlattices are two important ordered nanostructures of great scientific interest. Although both types of superlattices have been investigated extensively, a consensus has yet to be reached on their formation mechanisms. In this review article, the current research status of gas bubble and void superlattices in metals and alloys and their characterization, structural stability, and mechanistic modeling are summarized. The fundamental research goals to advance the mechanistic understanding of gas bubble and void superlattices are outlined.

36 MATERIALS SCIENCE↗
DOE OSTI2012

Magnetic anisotropy in composite CoFe{sub 2}O{sub 4}-BiFeO{sub 3} ultrathin films grown by pulsed-electron deposition

Many works have demonstrated perpendicular magnetic anisotropy in CoFe{sub 2}O{sub 4}-BiFeO{sub 3} (CFO-BFO) composites, which is commonly believed to originate from out-of-plane compressive strain in the CFO pillars due to the lattice mismatch with the BFO matrix. Others have shown that the pillar-matrix interface in similar NiFe{sub 2}O{sub 4}-BFO composites is fully relaxed. To study the origin of the magnetic anisotropy, composite films were grown on SrTiO{sub 3} with thicknesses ranging from 13 to 150 nm via pulsed electron deposition. In-plane compressive strain in the pillars is found for thinner samples, which induces in-plane magnetoelastic anisotropy. A model for the origin of this previously unreported strain is proposed and the results are contrasted with the thicker composite films found in the literature.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Structural Features of PLZT Films

Lead zirconate titanate (PZT) films doped with lanthanum, Pb({sub 1–х)}La{sub х}(Zr{sub 0.48}Ti{sub 0.52}) (х = 0, 0.02, 0.05, 0.08, or 0.01), have been investigated by electron microscopy and X-ray diffraction. Films were formed on Si–SiO{sub 2}–TiO{sub 2}–Pt substrates by chemical vapor deposition from a solution and annealed at temperatures T = 650 and 750°C. The main structural features of the films, differing them from undoped PZT films fabricated by the same method, have been established. It is found that doping with lanthanum delays the pyrochlore–perovskite transformation in the film bulk, i.e., in the regions distant from the film–substrate interface. The fraction of metastable pyrochlore phase increases with an increase in the La molar content in the films. The main reason for the delay is the deficit of lead in the intergranular perovskite space, especially in the upper part of the film. Annealing at T = 750°C reduces the content of pyrochlore phase but does not completely remove it, which was never observed for undoped PZT films. Doping with lanthanum leads to a change in the lattice period c and a tetragonal distortion of the perovskite lattice (c/a ratio). Hence, the [100] texture of the films obtained, in contrast to the typical [111] texture of PZT films, is due to the increase in the lattice mismatch between the film and platinum layer when lead atoms are replaced with lanthanum. Lattice distortions of “transrotational” character, whose value exceeds 160 deg/μm, are found to arise in growing crystals.

36 MATERIALS SCIENCE↗
NASA NTRS1982

Reduction of solar cell efficiency by edge defects across the back-surface-field junction - A developed perimeter model

Material imperfections, impurity clusters and fabrication defects across the back-surface-field junction can degrade the performance of high-efficiency solar cells. The degradation from defects appearing on the circumference of a solar cell is analyzed using a two-region developed perimeter device model. The width of the defective perimeter region is characterized by the range or the distance-of-influence of the defective edge and this width is about two diffusion lengths. The defective edge is characterized by a surface recombination velocity. Family of theoretical curves and numerical examples are presented to show that significant reduction of open-circuit voltage can occur in high-efficiency cells which are thin compared with the diffusion length. In one example, the degradation is decreased from 135 mV to 75 mV when the cell size is increased from 10 to 100 times the diffusion length in a thin cell whose thickness is 1% of the diffusion length.

Sah, C. T.↗
DOE OSTI2026

Achieving high rate performance in hybrid pristine-recycled cathodes using model-informed electrode designs

Direct recycling lithium-ion battery cathodes, a process that retains the engineered oxide structures from end-of-life materials, presents a cost-effective and energy-efficient alternative to other battery recycling methods. However, while direct-recycled cathodes have demonstrated performance comparable to that of pristine materials at low cycling rates, their high-rate performance remains uncertain. Morphology changes in cathode particles, a main mode of degradation, directly impact rate performance by limiting surface kinetics and solid-phase diffusion. If direct recycling processes do not sufficiently restore pristine-like morphologies, the recycled materials may retain structural defects that hinder high-rate performance. The present work uses a physics-based pseudo-2D model to simulate hybrid electrodes with pristine and artificially “aged/recycled” NMC materials to investigate potential impacts of incorporating performance-limited aged cathode materials into cells. The study highlights how differences in transport and kinetic properties can influence rate capabilities in mixed electrodes — particularly in high-loading cells in high-demand applications. However, model results also reveal a possible mitigation strategy via dual-layer electrode architectures with lower-performing materials positioned near the current collector. Simulations of 4.0 mAh cm −2 cells cycled at 4C using a dual-layer architecture provided approximately 5%–30% more capacity in constant-current protocols compared to homogeneously blended electrode architectures with the same loadings and mixed-material compositions. These findings highlight the importance of strategic electrode design in minimizing potential performance losses and facilitating the integration of recycled materials into high-performance batteries, advancing sustainable and cost-effective battery manufacturing.

25 ENERGY STORAGE↗
DOE OSTI2019

Deformation profile and interface-mediated defect interaction in Cu/CuZr nanolaminates: An effective-temperature description

Both simulations and experiments have suggested that Cu/CuZr nanolaminates are stronger and more ductile than their individual constituents due to interface-mediated interactions between plasticity carriers. In this work, we use the effective-temperature theories of dislocation and amorphous shear-transformation-zone (STZ) plasticity to study amorphous-crystalline interface (ACI)-mediated plasticity in Cu/CuZr nanolaminates under mechanical straining. The model is shown to capture reasonably well the measured deformation response when strained either in tension parallel to or in compression normal to the amorphous-crystalline interface. Our analysis indicates that increasing CuZr or decreasing Cu layer thickness increases the maximum flow stress for both perpendicular and parallel loading cases. Furthermore, for the cases of parallel and perpendicular loading, the maximum flow stress values are 3.4 and 2.5GPa, respectively. Furthermore, increasing the strain rate for the parallel loading case decreases the slip strain in the amorphous and crystalline layers. Additionally, for the perpendicular loading case, an increase in strain rate decreases the amorphous layer slip but increases the crystalline layer slip. In all slip strain analyses, maximum slip strain occurs at the ACI, thus indicating that plasticity carriers accumulate at the interface and are absorbed there. These findings indicate a significant anisotropy in strength with greater sensitivity to layer thickness for the case of tensile loading parallel to the ACI. Further findings signify that slip strain is more sensitive when the nanolaminate is compressed perpendicular to the ACI.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Methods to accelerate high-throughput screening of atomic qubit candidates in van der Waals materials

The discovery of atom-like spin emitters associated with defects in two-dimensional (2D) wide-bandgap (WBG) semiconductors presents new opportunities for highly tunable and versatile qubits. So far, the study of such spin emitters has focused on defects in hexagonal boron nitride (hBN). However, hBN necessarily contains a high density of nuclear spins, which are expected to create a strong incoherent spin-bath that leads to poor coherence properties of spins hosted in the material. Therefore, identification of new qubit candidates in other 2DWBG materials is necessary. Given the time demands of ab initio methods, new approaches for rapid screening and calculations of identifying properties of suitable atom-like qubits are required. In this work, we present two new methods for rapid estimation of the zero-phonon line (ZPL), a key property of atomic qubits in WBG materials. First, the ZPL is calculated by exploiting Janak’s theorem. For finite changes in occupation, we provide the leading-order estimate of the correction to the ZPL obtained using Janak’s theorem, which is more rapid than the standard method (ΔSCF). Next, we demonstrate an approach to converging excited states that is faster for systems with small strain than the standard approach used in the ΔSCF method. We illustrate these methods using the case of the singly negatively charged calcium vacancy in SiS2, which we are the first to propose as a qubit candidate. This work has the potential to assist in accelerating the high-throughput search for quantum defects in materials, with applications in quantum sensing and quantum computing.

Kuate Defo, Rodrick (ORCID:0000000242788196)↗
DOE OSTI2011

Study of the fragmentation of a displacement cascade into subcascades within the Binary Collision Approximation framework

When a material is subjected to irradiation, many primary defects are created at the atomic level by sequences of ballistic collision events to form highly disordered regions defined as displacement cascades. The long term evolution of materials under irradiation is dictated by the number and the spatial distribution of the surviving defects in the displacement cascade. The peculiar power law shape of collision cross sections is responsible for the fractal feature of atomic trajectories set and then the fragmentation of a displacement cascade into smaller subcascades. We present a criterion to describe the fragmentation of a displacement cascade into subcascades and to calculate the volume fraction of subcascades in the overall cascade due to this fragmentation. Such a volume fraction then provides a natural framework to estimate the efficiency of different projectiles to induce phase transformation or amorphisation in solids under irradiation. From this definition of the fragmentation of a displacement cascade, this work gives some new insights to compare different irradiations performed with different particles.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Characterization of bond line discontinuities in a high-Mn TWIP steel pipe welded by HF-ERW

In this work, the microstructure and defects in a high-frequency electrical resistance welded (HF-ERW) pipe of high-Mn twinning-induced plasticity (TWIP) steel were characterized. The microstructure of the base metal and the bond line were examined using both optical microscopy and scanning electron microscopy. The features of the bond line were similar to those of conventional steel. Simultaneously, the circumferential ductility was evaluated via a flaring test. It was concluded that the deterioration of the circumferential ductility in a high-Mn TWIP steel pipe was caused by irregular shaped oxide defects and a penetrator that had been formed during welding. Specifically, the penetrator, which is composed of MnO and Mn{sub 2}SiO{sub 4}, was found to be the most influential on the circumferential ductility of the welded pipe. The penetrator was analyzed using both an electron probe micro analyzer and transmission electron microscopy, and the formation sequence of the penetrator was evaluated. - Highlights: •This study focused on applying the HF-ERW process to the seam welding of expandable pipe using TWIP steels. •For improvement of the circumferential ductility, deterioration factors were characterized. •Penetrator which would mainly deteriorate the circumferential ductility consisted of round MnO and Mn{sub 2}SiO{sub 4}. •Metallurgical evidence of existing theory regarding the mechanism of defect formation during the HF-ERW was characterized.

36 MATERIALS SCIENCE↗
DOE OSTI2014

New insights on P-related paramagnetic point defects in irradiated phosphate glasses: Impact of glass network type and irradiation dose

P-related paramagnetic point defects were studied in irradiated Yb-doped phosphate glasses by electron paramagnetic resonance spectroscopy (X and Q-bands). A strong impact of the glass network type on the defect nature is shown. In all glasses, r-POHC defects formation is in strong correlation with Q{sup 2} tetrahedra amount supporting the structure of r-POHC. Ultra-phosphate glasses contain the larger defect type: Peroxy radicals, P{sub 1}, P{sub 2}, and P{sub 4} defects whose formation is linked to Q{sup 3} tetrahedra presence. In meta-phosphate and poly-phosphate glasses, peroxy radicals appear with r-POHC thermal recovery. In meta-phosphate glasses, a combination of P{sub 1} and P{sub 3} defects was evidenced for the first time, whereas in poly-phosphate glasses, only P{sub 3} defects were identified. Dose effect as well as defect recovery were analyzed.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
NASA NTRS1972

Ultrasonic scanning system for inspection of brazed tube joints

An ultrasonic scanning system used to inspect and evaluate in-place brazed tube joints is considered. The system was designed, developed, and built especially for nondestructive testing and was selected because of its known response to brazing defects not associated with material density changes. The scan system is capable of scanning brazed joints in union, tee, elbow and cross configuration of 3/16-inch through 5/8-inch diameters. It is capable of detecting brazed defects as small as 0.008 by 0.010-inch, which exceeds the 0.015-inch diameter defect resolution required by specification.

Haynes, J. L.↗
NASA NTRS1973

Outer skin protection of columbium Thermal Protection System (TPS) panels

A coated columbium alloy material system 0.04 centimeter thick was developed which provides for increased reliability to the load bearing character of the system in the event of physical damage to and loss of the exterior protective coating. The increased reliability to the load bearing columbium alloy (FS-85) was achieved by interposing an oxidation resistant columbium alloy (B-1) between the FS-85 alloy and a fused slurry silicide coating. The B-1 alloy was applied as a cladding to the FS-85 and the composite was fused slurry silicide coated. Results of material evaluation testing included cyclic oxidation testing of specimens with intentional coating defects, tensile testing of several material combinations exposed to reentry profile conditions, and emittance testing after cycling of up to 100 simulated reentries. The clad material, which was shown to provide greater reliability than unclad materials, holds significant promise for use in the thermal protection system of hypersonic reentry vehicles.

Culp, J. D.↗
NASA NTRS1978

Ion beam technology applications study

Specific perceptions and possible ion beam technology applications were obtained as a result of a literature search and contact interviews with various institutions and individuals which took place over a 5-month period. The use of broad beam electron bombardment ion sources is assessed for materials deposition, removal, and alteration. Special techniques examined include: (1) cleaning, cutting, and texturing for surface treatment; (2) crosslinking of polymers, stress relief in deposited layers, and the creation of defect states in crystalline material by ion impact; and (3) ion implantation during epitaxial growth and the deposition of neutral materials sputtered by the ion beam. The aspects, advantages, and disadvantages of ion beam technology and the competitive role of alternative technologies are discussed.

Sellen, J. M., Jr.↗
NASA NTRS1979

Evaluation of candidate metals in a simulated space shuttle main engine environment for application as turbine blade dampers

The high-pressure pumps for the space shuttle main engine are driven by combustion products which are 50 percent H2 and 50 percent H2O (by weight). The Haynes alloy 188, used in the dampers, experienced erosion. The erosion producing characteristics of wet H2 were evaluated using a controlled environment produced by a ballistic compressor. Four candidate materials were evaluated: H-188, A-286, Pt/Rh and Rh. Rh was clearly the most erosion resistant. Comparisons with AISI 4340 and Fe specimens of known uniformity indicate that metallurgical defects in the candidate materials are primary contributors to the higher than usual erosion.

Caveny, L. H.↗