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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 1,351 records · Page 75
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Multi-scale study of the deformation mechanisms of thermoelectric p-type half-Heusler Hf 0.44 Zr 0.44 Ti 0.12 CoSb 0.8 Sn 0.2

Increasing the figure of merit ZT of thermoelectric (TE) alloys is a challenge that is currently attempted through various metallurgy methods, including nanostructuring and dislocation engineering. Microstructures with such a level of complexity raise questions about the mechanical reliability of these new materials. Indeed, despite the values of hardness and elastic modulus known for the clear majority of TE materials, the data on deformation mechanisms are still rare. Focusing on the nanostructured p-type half-Heusler Hf 0.44 Zr 0.44 Ti 0.12 CoSb 0.8 Sn 0.2 , our multi-scale study aims to analyze the deformation mechanisms. Experiments conducted at macro-, meso-, and micro-scale are designed to trigger and assess plasticity mechanisms. Compression testing on bulk samples subject to a confining pressure environment and temperature leads to an exclusive brittle failure. The mixed-mode failure mechanisms involve switching between intra- and inter-granular crack propagation, depending on the grain size met by the crack tip. Cube-corner nanoindentation at meso-scale generates cracks and enables fracture toughness estimation, while TEM analysis of the crack tip area confirms no dislocation activity and 3D-Electron Back Scattered Diffraction technique confirms the mixed crack propagation behavior. At micro-scale, micro-pillar compression stress-strain curves and failure mechanisms are comparable with bulk samples testing analysis. These results can be used to provide design guidelines for more crack-resistant TE alloys.

Thermoelectricity↗
DOE OSTI2022

Two–Photon Polymerized Shape Memory Microfibers: A New Mechanical Characterization Method in Liquid

Two-photon polymerization (TPP) is widely used to create 3D micro- and nanoscale scaffolds for biological and mechanobiological studies, which often require the mechanical characterization of the TPP fabricated structures. To satisfy physiological requirements, most of the mechanical characterizations need to be conducted in liquid. However, previous characterizations of TPP fabricated structures are all conducted in air due to the limitation of conventional micro- and nanoscale mechanical testing methods. In this study, a new experimental method is reported for testing the mechanical properties of TPP-printed microfibers in liquid. The experiments show that the mechanical behaviors of the microfibers tested in liquid are significantly different from those tested in air. By controlling the TPP writing parameters, the mechanical properties of the microfibers can be tailored over a wide range to meet a variety of mechanobiology applications. In addition, it is found that, in water, the plasticly deformed microfibers can return to their predeformed shape after tensile strain is released. The shape recovery time is dependent on the size of microfibers. The experimental method represents a significant advancement in mechanical testing of TPP fabricated structures and may help release the full potential of TPP fabricated 3D tissue scaffolds for mechanobiological studies.

36 MATERIALS SCIENCE↗
DOE OSTI2016

A reduced Iwan model that includes pinning for bolted joint mechanics

Bolted joints are prevalent in most assembled structures; however, predictive models for their behavior do not exist. Calibrated models, such as the Iwan model, are able to predict the response of a jointed structure over a range of excitations once calibrated at a nominal load. The Iwan model, though, is not widely adopted due to the high computational expense of implementation. To address this, an analytical solution of the Iwan model is derived under the hypothesis that for an arbitrary load reversal, there is a new distribution of dry friction elements, which are now stuck, that approximately resemble a scaled version of the original distribution of dry friction elements. The dry friction elements internal to the Iwan model do not have a uniform set of parameters and are described by a distribution of parameters, i.e., which internal dry friction elements are stuck or slipping at a given load, that ultimately governs the behavior of the joint as it transitions from microslip to macroslip. This hypothesis allows the model to require no information from previous loading cycles. Additionally, the model is extended to include the pinning behavior inherent in a bolted joint. Modifications of the resulting framework are discussed to highlight how the constitutive model for friction can be changed (in the case of an Iwan–Stribeck formulation) or how the distribution of dry friction elements can be changed (as is the case for the Iwan plasticity model). Finally, the reduced Iwan plus pinning model is then applied to the Brake–Reuß beam in order to discuss methods to deduce model parameters from experimental data.

42 ENGINEERING↗
DOE OSTI2023

Atomistic simulations of He bubbles in Beryllium

Formation of He bubbles can have a significant effect on the microstructural evolution and properties of irradiated materials. In this report, we use atomistic simulations based on machine learning potentials to investigate the fundamental behavior of He bubbles in Be, with a specific focus on the shape, stability, and diffusivity of bubbles. Stability of He bubbles is quantified in terms of formation energies, which are determined as a function of the ratio of He/V. We find that He bubbles become unstable with respect to plastic deformation through punch-out dislocations around the bubble when the He/V ratio is larger than ~1.25, and the punch-out process induces the change of the regular bubble shape. In general, the bubble shape of He in Be is found to be ellipsoid-like. It is also found that for a fixed He/V ratio, the bubble attracts vacancies to become larger in size. If the bubble size is constant, the bubble attracts additional He atoms until the punch-out reaction occurs. The dominant diffusion mechanism of He bubbles changes from surface diffusion to volume diffusion as the temperature is increased, with a crossover occurring at about 900 K.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2016

Microstructure and deformation behavior of nickel based superalloy Inconel 740 prepared by electron beam smelting

Electron beam smelting (EBS) has been used to fabricate the Inconel 740 superalloy. Microstructures, hardness, and deformation characteristics of the alloy are studied. It is observed that carbides and fine secondary phase nuclei are distributed in the hot worked EBS 740 superalloy. The Ostwald ripening occurs during solution treatment and leads to aggregation of the γ′ precipitates, the size of γ′ precipitates varies from several nanometers to more than one hundred nanometers as a result. The average size of the secondary phase is < 30 nm after aging treatment and the average Vickers hardness is measured to be about 370. The critical shear stress is calculated to be 0.627 GPa with governing mechanism of shearing, causing a stronger strengthening effect than the traditionally prepared Inconel 740 superalloy. The compression behavior indicates that the EBS 740 superalloy shows higher flow stress than 740H at low Zener-Hollomon parameter, which may arise from the undissolved γ′ precipitates and higher activation energy Q. The tensile results show that the fracture surface exhibits a ductile fracture pattern, in contrast to no obvious plastic deformation on the macroscopic fracture. Crack propagation proceeds in a transgranular fracture mode with facets and voids presented on the fracture surface. - Graphical abstract: Electron beam smelting (EBS) has been used to fabricate the Inconel 740 superalloy. Microstructures, hardness, and deformation characteristics of the alloy are studied. The average size of the secondary phase is < 30 nm after aging treatment and the average Vickers hardness is measured to be about 370. The critical shear stress is calculated to be 0.627 GPa with governing mechanism of shearing, causing a stronger strengthening effect than the traditionally prepared Inconel 740 superalloy. The EBS 740 superalloy shows higher flow stress than 740H at low Zener-Hollomon parameter, which may arise from the undissolved γ′ precipitates and higher activation energy Q. The EBS technology shows encouraging potential in preparation of nickel-based superalloys. Morphologies of γ′ precipitates and Vickers hardness as well as hot compression curves for electron beam smelting 740 superalloy. - Highlights: • Electron beam smelting, a novel method, was used to prepare the Inconel 740 superalloy. • The average size of the γ′ precipitates after aging treatment is < 30 nm. • The shearing mode generates a stronger strengthening effect than the traditional 740. • At low Zener-Hollomon parameter, the EBS 740 shows higher flow stress than 740H.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Analysis of xRAGE and flag high explosive burn models with PBX 9404 cylinder tests

High explosives are energetic materials that release their chemical energy in a short interval of time. They are able to generate extreme heat and pressure by a shock driven chemical decomposition reaction, which makes them valuable tools that must be understood. This study investigated the accuracy and performance of two Los Alamos National Laboratory hydrodynamic codes, which are used to determine the behavior of explosives within a variety of systems: xRAGE which utilizes an Eulerian mesh, and FLAG with utilizes a Lagrangian mesh. Various programmed and reactive burn models within both codes were tested using a copper cylinder expansion test. The test was based on a recent experimental setup which contained the plastic bonded explosive PBX 9404. Detonation velocity versus time curves for this explosive were obtained using Photon Doppler Velocimetry (PDV). The modeled results from each of the burn models tested were then compared to one another and to the experimental results. This study validate

36 MATERIALS SCIENCE↗
NASA NTRS1985

Nonlinear quasi-fracture behavior of polymers

This paper deals with the nonlinear quasi-fracture behavior of polymers. Using the finite element method, the quasi-fracture model composed of an isolated craze opening with a nonlinear boundary envelope forces represented by oriented fibril domains is analyzed in simply-stressed rectangular plate. The stress distribution, the displacement profile, as well as the yield or plastic or flow zone adjacent to the craze tips are obtained. It is found that the variation of the stress distribution near the craze tip is not as sharp as that for an elastic crack. The initial load required for yielding or flowing is greater for the quasifracture as compared with that for a classical fracture. Under the same load the yield or flow zone is somewhat smaller as compared with that obtained on the basis of linear elastic-plastic fracture mechanics theory.

Sun, B. N.↗
NASA NTRS1989

Elevated temperature crack growth

Alloy 718 crack growth experiments were conducted to assess the ability of the selected path-independent (P-I) integrals to describe the elevated temperature crack growth behavior. These tests were performed on single edge notch (SEN) specimens under displacement control with multiple extensometers to monitor the specimen and crack mouth opening displacement (CMOD). The displacements in these tests were sufficiently high to induce bulk cyclic inelastic deformation of the specimen. Under these conditions, the linear elastic fracture mechanics (LEFM) parameter K does not correlate the crack growth data. The experimentally measured displacement gradients at the end of specimen gage length were used as the boundary conditions in elastic-plastic finite element method (FEM) analyses. These analyses were performed with a node release approach using CYANIDE, a GEAE FEM code, which included a gap element which is capable of efficiently simulating crack closure. Excellent correlation was obtained between the experimentally measured and predicted variation of stress and CMOD with crack length and the stress-CMOD loops for Alloy 718 tests conducted at 538 C. This confirmed the accuracy of the FEM crack growth simulation approach. The experimentally measured crack growth rate data correlated well the selected P-I integrals. These investigations have produced significant progress in developing P-I integrals as non-linear fracture mechanics parameters. The results suggest that this methodology has the potential of accurately describing elevated temperature crack growth behavior under the combined influence of thermal cycling and bulk elastic-inelastic deformation states.

Kim, K. S.↗
DOE OSTI2018

Fuel properties and steam reactivity of solid waste streams from contingency bases

Highlights: • Composite waste fuels were prepared for characterizing fuel property and reactivity. • Characterization of the composite fuels can be predicted by individual components. • A simple methodology for characterizing multi-component solid wastes was validated. • Plastic components increase carbon content and HHV of solid waste fuels. • Effects of fuel composition on syngas production and composition were explored. - Abstract: The solid waste generated from military contingency bases (CBs) is a potential fuel for appropriately-scaled, waste to energy (WTE) systems. To inform WTE system design, fuel properties of seventeen components of synthetic contingency-base waste recipes from the literature were characterized for ultimate analysis, heating values, proximate analysis and reactivity in a steam atmosphere at three temperature typical of gasification conditions. A simple mathematical approach was applied to predict the properties and reactive behavior of composite mixtures using the weighted sum of the corresponding components, assuming negligible interaction between components. The method was validated using prepared composite mixture samples. In addition, chemical equilibrium calculations for steam gasification of the composite samples were conducted to explore the effects of waste composition variability on syngas production and composition.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2018

In-situ high-energy X-ray characterization of neutron irradiated HT-UPS stainless steel under tensile deformation

Here, the tensile deformation behavior of a high-temperature, ultrafine-precipitate strengthened (HT-UPS) stainless steel was characterized in-situ with high-energy X-ray diffraction at 20 and 400 °C. The HT-UPS samples were neutron irradiated to 3 dpa at 400 °C. Significant irradiation hardening and ductility loss were observed at both temperatures. Lattice strain evolutions of the irradiated samples showed a strong linear response up to near the onset of the macroscopic yield, in contrast to the unirradiated HT-UPS which showed a pronounced non-linear behavior well below the macroscopic yield. While the room temperature diffraction elastic moduli in the longitudinal direction increased after irradiation, the 400 degrees C moduli were similar before and after irradiation. The evolution of the {200} lattice strain parallel to the loading axis (ε L {200} ) showed unique characteristics: in the plastic regime, the evolution of (ε L {200} ) after yield is temperature-dependent in the unirradiated specimens but temperature-independent in the irradiated specimens; and the value of (ε L {200} ) at the yield is an irradiation-sensitive, temperature-independent . parameter. The evolution of (ε L {200} ) corresponds well with the dislocation density evolution, and is an effective probe of the deformation-induced long-range internal stresses in the HT-UPS steel.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Visualization and validation of twin nucleation and early-stage growth in magnesium

The abrupt occurrence of twinning when Mg is deformed leads to a highly anisotropic response, making it too unreliable for structural use and too unpredictable for observation. Here, we describe an in-situ transmission electron microscopy experiment on Mg crystals with strategically designed geometries for visualization of a long-proposed but unverified twinning mechanism. Combining with atomistic simulations and topological analysis, we conclude that twin nucleation occurs through a pure-shuffle mechanism that requires prismatic-basal transformations. Also, we verified a crystal geometry dependent twin growth mechanism, that is the early-stage growth associated with instability of plasticity flow, which can be dominated either by slower movement of prismatic-basal boundary steps, or by faster glide-shuffle along the twinning plane. The fundamental understanding of twinning provides a pathway to understand deformation from a scientific standpoint and the microstructure design principles to engineer metals with enhanced behavior from a technological standpoint.

36 MATERIALS SCIENCE↗
DOE OSTI2020

In Situ Synchrotron X-ray Diffraction Investigations of the Nonlinear Deformation Behavior of a Low Modulus β -Type Ti36Nb5Zr Alloy

The low modulus β-type Ti alloys usually have peculiar deformation behaviors due to their low phase stability. However, the study of the underlying mechanisms is challenging since some physical mechanisms are fully reversible after the release of the load. In this paper, the deformation behavior of a low modulus β-type Ti36Nb5Zr alloy was investigated with the aid of in situ synchrotron X-ray diffraction (SXRD) during tensile loading. The evolution of lattice strains and relative integrated diffraction peak intensities of both the β and α” phases were analyzed to determine the characteristics of the potential deformation mechanisms. Upon loading, the α” diffraction spots appeared at specific azimuth angles of the two-dimensional SXRD patterns due to the <110> fiber texture of original β grains and the selection of favorable martensitic variants. The nonlinear deformation behavior originated from a reversible stress-induced martensitic transformation (SIMT). However, the SIMT contributed a little to the large recoverable strain of over 2.0%, which was dominated by the elastic deformation of the β phase. Various deformation mechanisms were activated successively at different applied strains, including elastic deformation, SIMT and plastic deformation. Our investigations provide in-depth understandings of the deformation mechanisms in β-type Ti alloys with low elastic modulus.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Effects of UV Aging on the Cracking of Titanium Oxide Layer on Poly(ethylene terephthalate) Substrate: Preprint

Thin oxide and metal films deposited on polymer substrates is an emerging technology for advanced reflectors for concentrated solar power applications, due to their unique combination of light weight, flexibility and inexpensive manufacture. Thus far, there is little knowledge on the mechanical integrity or structural persistence of such multi-layer thin film systems under long-term environmental aging. In this paper, the cracking of a brittle titanium dioxide layer deposited onto elasto-plastic poly(ethylene terephthalate) (PET) substrate is studied through a combination of experiment and modeling. In-situ fragmentation tests have been conducted to monitor the onset and evolution of cracks both on pristine and on samples aged with ultraviolet (UV) light. An analytical model is presented to simulate the cracking behavior and to predict the effects of UV aging. Based on preliminary experimental observation, the effect of aging is divided into three aspects and analyzed independently: mechanical property degradation of the polymer substrate; degradation of the interlayer between substrate and oxide coating; and internal stress-induced cracks on the oxide coating.

14 SOLAR ENERGY↗
DOE OSTI2019

Grain-Refined Microstructure and Hard Surface Layer Produced by SMRGT Process for Improved Corrosion Behavior of Mg-3Al-1Zn Alloy

To improve the surface properties and performance, a grain-refined surface layer was produced on AZ31B Mg alloy by a newly developed surface nano-crystallization and hardening process called surface mechanical rolling grinding treatment (SMRGT). The grain size refinement and minimal surface hardening were confirmed by the microstructure observations, XRD results and microhardness tests and were attributed to the multipass small strain-induced plastic deformation of the material during the SMRGT process. A nano-grain surface layer (average grain size of ~ 100 nm) and a graded microhardness variation (average ~ 113 HV adjacent to surface) along the thickness direction were generated. The E{sub corr} values of the as-SMRGTed samples were − 1.43 ± 0.03 and − 1.42 ± 0.02 V, increasing by ~ 30-40 mV compared with the values of the as-received (AR) sample (− 1.46 ± 0.02 V), corresponding to i{sub corr} ranging from 3.0 × 10{sup −5} to 1.0 × 10{sup −5} and 5.0 × 10{sup −6} A/cm{sup 2}, respectively. Charge transfer resistance (R{sub ct}) increased from 93.4 to 292.4 and 578.3 Ω (~ 3-6 times) with the increasing number of SMRGT passes. The corrosion resistance improvement was attributed mainly to the dramatic strain-induced surface grain refinement and minimal surface hardening that give rise to a more smooth and densely packed surface state.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Considering interplay between multiple physical phenomena to elucidate single crystal-like texture, phase transformations, and mechanical behavior of directed energy deposited SS316L

A widespread implementation of large scale additive manufacturing (AM) processes, such as wire arc-directed energy deposition (WA-DED) AM can transform the current manufacturing supply chain networks. Naturally, such implementation requires control of the microstructural attributes, such as texture and phase evolution in the processed alloys. Currently, the texture evolution in fusion-based AM (F-BAM) processes is majorly rationalized by the phenomena occurring only during solidification. However, such rationalization is insufficient for understanding the evolution of primary and secondary crystallographic orientations, and consequently, fails to offer a comprehensive understanding and control of overall texture in F-BAM processed alloys. To this end, we report a single crystal (SX)-like texture in WA-DED processed SS316L for the first time. Furthermore, we assess the physical phenomena that may lead to such unique microstructural evolution during WA-DED AM. Subsequently, using microstructural characterization spanning the build height and thermomechanical simulations we investigate the effect of competitive growth and epitaxial growth occurring during solidification and thermally induced plastic deformation occurring post solidification on the overall texture of WA-DED processed SS316L. A spatial variation in solidification pathway is also established and correlated with variation in undercoolings across the build. Tensile tests revealed a strong orientation dependence of deformation mechanisms with over 110% elongation to failure of specimens deformed along <011>. Such anisotropy is rationalized using Schmid's analysis of dislocation slip and deformation twinning. Importantly, overall, the mechanisms outlined in this work will facilitate an enhanced understanding and subsequent control of texture evolution, solidification behavior and mechanical behavior of WA-DED processed steels.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Laser Additive Manufacturing of (Ti-6Al-4V)/10 wt.% Ag Composite Using Spherical Powders to Reduce Wear and Friction

In order to extend the service lifetime of Ti-6Al-4V-based components, friction and wear behaviors of Ti-6Al-4V alloys needed to be further improved. Laser additive manufacturing with a moving laser beam was used to prepare (Ti-6Al-4V)/10 wt.% Ag samples, on a three-dimensional RC-SLM400 printer with laser powers of 2-10 kW. (Ti-6Al-4V)/10 wt.% Ag samples were successfully printed using spherical powders prepared by gas atomization process (SPGAP) and combustion reaction (SP-CR). The tribological properties of the as-prepared samples sliding against Si{sub 3}N{sub 4} balls were examined using a ball-on-disk tribometer. The results showed that the tribological behavior of (Ti-6Al-4V)/10 wt.% Ag printed by SP-CR was better than that of the sample printed by SPGAP. The low friction and reduced wear were mainly attributed to the formation of the lubrication layer containing large amounts of silver, which can exhibit an excellent deformation and plastic ductility. It effectively reduced the friction resistance and material loss and provided the good lubrication for 0-80 min, resulting in low friction and reduced wear of the samples prepared by SP-CR.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Development of Predictive Model for Accurate Rupture Time from Multi-Axial Creep in Alloy 709 with Physics-Based Simulations

A physics-based model is developed to predict multiaxial creep behavior in Alloy 709 (A709), an advanced austenitic stainless steel intended for high-temperature applications such as Sodium Fast Reactors (SFRs). Compared to conventional stainless steels like 316H, A709 offers superior high-temperature performance; however, comprehensive data on its multiaxial creep response remain limited. To address this gap, a crystal plasticity finite element (CPFE) framework is used to simulate the deformation and failure mechanisms of A709 under multiaxial loading conditions. The model incorporates an extended Hu-Cocks dislocation creep formulation that accounts for precipitation effects, along with the Sham–Needleman model to capture grain boundary cavitation-driven failure. These advanced constitutive models enable a detailed understanding of the interplay between microstructural evolution and macroscopic creep response. Furthermore, the study evaluates the predictive accuracy of various effective stress measures in estimating creep rupture life, leveraging simulated multiaxial creep data. The findings provide critical insights into the applicability of different stress measures for engineering design and life prediction of A709 components operating under complex loading conditions. This work contributes to improving the reliability of high-temperature structural components by advancing predictive modeling capabilities for advanced austenitic steels.

Alloy 709↗