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At least 1,369 records · Page 76
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Influence of printing parameters on the mechanical behavior of 3D-printed SS316L parts manufactured using laser hot wire directed energy deposition

Hybrid manufacturing combines the simultaneous benefits of additive manufacturing (complex geometries, part consolidation, and mass customization) with the advantages of subtractive manufacturing (superior surface finish and enhanced dimensional accuracies) by integrating a suite of complementary traditional processes into a base platform of additive manufacturing. The use of hybrid technology has grown in recent years given its capabilities on repairing metallic structures, producing parts with conformal cooling features, and manufacturing functionally graded products. These kinds of capabilities are of great interest to the medical implant, energy, automotive, maritime, and aerospace industry sectors, among many other fields. This work investigated the mechanical properties of stainless steel (SS) 316L as a function of different tool paths strategies using an integrated 5-axis CNC hybrid Mazak system with a laser hot wire deposition system (LHWDS). This study includes the evaluation of different printing parameters and their impact on the quality of the printed bead as well as the incorporation of a structure–property material relationship based on the mechanical performance of the manufactured coupons.

36 MATERIALS SCIENCE↗
DOE OSTI2021

In-depth understanding of molecular mechanisms of aldehyde toxicity to engineer robust Saccharomyces cerevisiae

Aldehydes are ubiquitous electrophilic compounds that ferment microorganisms including Saccharomyces cerevisiae encounter during the fermentation processes to produce food, fuels, chemicals, and pharmaceuticals. Aldehydes pose severe toxicity to the growth and metabolism of the S. cerevisiae through a variety of toxic molecular mechanisms, predominantly via damaging macromolecules and hampering the production of targeted compounds. Compounds with aldehyde functional groups are far more toxic to S. cerevisiae than all other functional classes, and toxic potency depends on physicochemical characteristics of aldehydes. The yeast synthetic biology community established a design–build–test–learn framework to develop S. cerevisiae cell factories to valorize the sustainable and renewable biomass, including the lignin-derived substrates. However, thermochemically pretreated biomass-derived substrate streams contain diverse aldehydes (e.g., glycolaldehyde and furfural), and biological conversions routes of lignocellulosic compounds consist of toxic aldehyde intermediates (e.g., formaldehyde and methylglyoxal), and some of the high-value targeted products have aldehyde functional group (e.g., vanillin and benzaldehyde). Numerous studies comprehensively characterized both single and additive effects of aldehyde toxicity via systems biology investigations, and novel molecular approaches have been discovered to overcome the aldehyde toxicity. Based on those novel approaches, researchers successfully developed synthetic yeast cell factories to convert lignocellulosic substrates to valuable products, including aldehyde compounds. Here, we highlight the salient relationship of physicochemical charac- teristics and molecular toxicity of aldehydes, the molecular detoxification and macromolecules protection mechanisms of aldehydes, and the advances of engineering robust S. cerevisiae against complex mixtures of aldehyde inhibitors.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2020

Thermo-mechanical modeling and experimental validation for multilayered metallic microstructures

This paper presents thermo-mechanical modeling on multilayered metallic microstructures consisting of two bilayers that enable 3D deployment once being Joule heated. Additionally, a representative design of such microstructures, as well as their working principle is introduced. Furthermore, a mathematical model is derived using Euler–Bernoulli beam theory, and analytical solutions describing out-of-plane displacement of the multilayered microstructures when uniformly heated, which is validated by finite element analysis. Parametric analysis on thermal load and dimensional change of beam shows a good agreement between the analytical solutions and results given by finite element analysis. The phases of the near-equiatomic NiTi layer are analyzed by EDS and XRD, which prove to be austenite during the Joule heating process. The mechanical properties of austenite NiTi are incorporated into the analytical solutions that provides a good estimation of 3D deployment of microstructures made of NiTi and aluminum. The experimental results provide an approximately 7 µm out-of-plane deployment by applying a uniform temperature increase of 132 K, and parametric analysis on the dimension of top aluminum beam offers another promising approach to larger 3D deployment. The proposed mathematical model provides an efficient tool for predicting the out-of-plane deployment of such multilayered microstructures.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Field validation of dynamic mechanical torque measurements using fiber-optic strain sensors for geared wind turbines

Abstract Accurate knowledge of the mechanical loads of wind turbine gearboxes has become essential in modern, highly loaded gearbox designs, as maintaining or even improving gearbox reliability with increasing torque density demands is proving to be challenging. Unfortunately, the traditional method of measuring dynamic mechanical torque using strain gauges placed on the outer surface of a rotating shaft and transmitting the resulting signal is unsuitable for serial deployment due to technical and economic constraints. An alternative method based on fiber-optic strain sensors placed on the stationary outer surface of the gearbox ring gear has been proposed. Like shaft torsion, the radial deformation of the ring gear is proportionate to the rotor torque. Placing the sensors on a stationary component is a cost-effective alternative for serial implementation because the need for complex and expensive data transfer via wireless transmission or a slip ring is eliminated. In this paper, we present the results of an extensive field experiment conducted to evaluate the torque measurement accuracy of this novel sensing solution installed on the gearbox of a Gamesa G97 2-MW wind turbine at the National Renewable Energy Laboratory’s Flatirons Campus. Torque measurements derived from fiber-optic strain sensors placed on the ring gear of the planetary stage are compared to conventional torque measurements from strain gauges placed on the main shaft. Two different torque estimation data processing methods were evaluated, with the method based on operational deflection shapes providing the most accurate results with an average normalized root mean square error below 0.7% for a load revolution distribution analysis. The effect of operating conditions on the torque estimate was also investigated, and the third planet-passing operational deflection shape was found to be the least sensitive to nontorque load-related effects. The fiber-optic strain sensors’ successful operation during the complete test campaign has demonstrated a robust and accurate solution for fleet-wide enhanced gearbox remaining useful life estimation.

17 WIND ENERGY↗
DOE OSTI2025

Mechanical and Thermal Characterization of Additively Manufactured Carbon/Nylon 12 and Carbon/PEEK Composites

This study explores additive manufacturing of carbon fiber-reinforced thermoplastic composites using the Composite-Based Additive Manufacturing (CBAM) process. Carbon/Nylon 12 and Carbon/PEEK composites were fabricated and evaluated through mechanical (compression, tensile, flexural, and impact) and thermal (DSC and TGA) tests. Carbon/PEEK exhibited superior mechanical performance, with 97.5% higher tensile strength, 79.8% higher elastic modulus, and 59.6% higher flexural strength compared to Carbon/Nylon 12. Thermal testing showed that Carbon/PEEK had higher thermal stability, beginning degradation at 350 °C versus 298 °C for Carbon/Nylon. These results indicate that CBAM-fabricated Carbon/PEEK composites are suitable for applications requiring high strength and temperature resistance.

Additive manufacturing↗
DOE OSTI2019

Mechanical, Fire Retardant, Water Absorption and Soil Biodegradation Properties of Poly(3-hydroxy-butyrate-co-3-valerate) Nanofilms

Biopolymers provide potential substitution to synthetic polymers derived from scarce petroleum materials which are not environmental friendly and biodegradable. However, there exists challenging or unanswered questions for biopolymers to be used in biomedical, film packaging, automobile, construction and commercial industries such as their mechanical performance, thermal and fire retardancy, and durability when exposed to water. In this study, we investigated one such potential biopolymer, poly(3-hydroxy-butyrate-co-3-valerate) (PHBV) for the aforementioned properties. At first, 0–15 wt% halloysite nanotubes (HNTs) was dispersed in PHBV polymer using ultrasonication process in presence of chloroform solvent. The solvent was then evaporated and PHBV/HNTs films were prepared by solution casting method. PHBV films without HNTs (neat) were also prepared for baseline comparison. Thermogravimetric analysis (TGA) and tensile tests were then performed to study the thermal and mechanical properties of these films. The horizontal burning test (HBT) was also carried out to investigate the fire retardancy behavior. Finally, the water absorption and soil biodegradability behavior of these composites were investigated by submerging the films in water and Alabama soil conditions. PHBV films with 3 wt% loading showed optimum enhancement in thermal stability and tensile properties. In contrast, films with 10–15 wt% HNTs loading showed superior fire-retardancy, better water resistance and faster soil degradation over neat counterpart.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2019

First Principle Mechanical and Thermodynamic Properties of Some TbX (X = S, Se) Compounds

The mechanical and thermodynamic results of some terbium chalcogenides, TbX (X = S, Se) compounds have been examined using full-potential linear augmented plane wave (FP-LAPW) method based on density functional theory. The local spin density approximation with Hubbard potential (LSDA+U) has been used for proper treatment of 4f-electrons of Tb. The magnetic moment of TbS and TbSe was calculated to be 5.44μ{sub B} and 5.57μ{sub B}, respectively. The ground state properties such as lattice parameter, bulk modulus, and pressure derivative of bulk modulus were obtained and found in good agreement with already available theory and experiment results. The mechanical properties such as Young modulus (E), shear modulus (G), Poisson ratio (υ), Cauchy pressure and B/G ratio were also predicted. Further, in thermodynamic properties, Debye temperatures (θ{sub D}), specific heats at constant volume(C{sub V}), thermal expansion co-efficient (α), and entropies (S) and their behavior with high temperature(0–1200 K) and pressure (0–50 GPa) were also predicted.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2019

Improvement in the Crystallographic Phase Content and Superconducting Properties of Mechanically Alloyed MgB{sub 2}

In this paper, the results of the superconductivity evaluation of MgB{sub 2} intermetallic-based superconducting materials prepared through mechanical alloying are reported. The formation of the MgB{sub 2} intermetallic phase took place through an intermediate phase reaction at the solid-state reaction temperature, which tends to favor single-phase materials. The annealing of mechanically milled Mg and B powders resulted in the highest mass fraction of MgB{sub 2} observed in this study, reaching more than 90% after annealing at 900 °C for 1 h. At that point, there were still second phases present consisting of Mg, MgO, and Fe{sub 2}B. Improved superconducting properties were obtained in samples sintered at temperatures of 850 °C and 900 °C that had a low resistivity, low critical temperature gap values, and a high residual resistivity ratio (RRR).

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2019

The Effect of Zinc on the Structural, Electrical, and Mechanical Properties of YBCO-123 Superconducting Nanoparticles Prepared by an Acetate-Based Sol-Gel Process

In this study, zinc (Zn)-doped YBaCuO (YBCO)-123-based high-temperature superconducting samples were produced using the sol-gel method, which is commonly used for preparing nanosize materials. Zn ions were substituted by Cu ions (YBa{sub 2}Cu{sub 3-x}Zn{sub x}O), and Zn doping effects on structural, electrical, and mechanical properties of the YBCO-123 superconductors were examined in detail. Undoped sample was prepared under same conditions. X-ray diffraction analysis (XRD) was used to determine phase analysis and lattice parameters of the superconducting samples. To analyze the microstructure properties, scanning electron microscope (SEM) measurements were performed. Resistivity and microhardness measurements were also carried out for superconducting and mechanic properties, respectively. Vickers microhardness, young modulus, fracture toughness, and yield strength values of the samples were calculated. Microhardness measurements were analyzed using the Kick’s law, proportional sample resistance (PSR) model, EPD model, the Hays-Kendall (HK) approach, and indentation-induced cracking (IIC) model.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2020

Corrosion and Mechanical Performance of Grade 92 Ferritic-Martensitic Steel After Exposure to Supercritical Carbon Dioxide

Grade 92 ferritic-martensitic steel is a candidate alloy for medium temperature (< 550 °C) components for the supercritical carbon dioxide (s-CO 2 ) Brayton cycle. 1000 hours exposures were performed on base and welded material in s-CO 2 at temperatures of 450 °C or 550 °C and compared to samples aged in Ar at 550 °C. Both s-CO 2 exposures resulted in a duplex oxide growth and carburization, with 450 °C exhibiting carburization in a power law diffusion profile up to a depth of 200-250 µm, while 550 °C showed a linear profile up to a depth of 100 µm. The different profiles indicate much slower precipitation and coarsening of carbides at the lower temperature, allowing carbon to diffuse deeper into the material. However, 450 °C produced improved mechanical properties while 550 °C produced deteriorated properties. This was due to the higher density of carbon near the metal–oxide interface which leads to significant carbide coarsening and, subsequently, crack initiation and early failure. Finally, additional exposure at 450 °C is predicted to increase deposited carbon, but further study would be needed to understand if and when carburization will produce a negative mechanical effect.

36 MATERIALS SCIENCE↗
DOE OSTI2021

A Mechanism for Carbon Depletion at Bondline of High-Frequency Electric-Resistance-Welded X70 Pipeline Steel

The bondline of electric-resistance-welded (ERW) linepipe steel, often etched white (i.e., ferrite) in optical microscopy, is generally believed to be carbon depleted. The mechanism for the carbon depletion, however, is not fully understood by researchers. To this end, here we used atom probe tomography (APT) to measure elemental segregation of the as-welded and post-weld heat-treated bondline regions of X70 linepipe welds. The thin vertical features at the bondline in the as-welded condition were identified as carbon-rich martensite-austenite (M-A) constituents, and the majority ferrite phase in the bondline was identified as carbon-depleted ferrite. Following the post-weld normalization, all alloying elements, except Nb and Mo, are homogenized across the bondline and heat-affected zone. The carbon depletion in the ERW bondline was accurately measured. A new mechanism for carbon depletion has been proposed using Scheil calculations of elemental partitioning during weld formation. Segregation of elements in the heat-affected zone was shown to follow the negligible partitioning local equilibrium (NPLE) kinetics for bainite transformation.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Temperature-Dependent Thermal and Mechanical Properties of a Wire Arc Additively Manufactured Low Transformation Temperature Steel

Recent research has studied the use of low transformation temperature (LTT) martensite steel as feedstock for wire arc additive manufacturing (WAAM) and low tensile residual stresses or compressive residual stresses were detected in the printed walls. These residual stress states help to improve printed product properties such as fatigue strength and corrosion resistance. However, the thermal and mechanical properties of WAAM printed LTT martensite steel walls are largely unknown. In this work, a printed LTT martensite steel was characterized for its thermal, metallurgical, and mechanical behavior at room and elevated temperatures. The temperature-dependent specific heat capacity, thermal expansion, atomic lattice spacing, and tensile properties were measured during both heating and cooling and related to observed microstructural features and computational thermodynamics predictions. These results revealed a large hysteresis in the martensitic transformation, with a martensite start temperature of 240 °C and austenite start temperature of 680 °C. Additional thermal cycles and specimen orientation did not affect the printed specimen austenite and martensite transformations. However, it was observed that the printed metal may exhibit tempering embrittlement at about 350 °C but further studies are needed to confirm that. Further, these results suggest that a temperature control of 250 °C to 350 °C during WAAM is needed to maximize the stress reduction potential of the LTT250 martensite steel. Opportunities for future implementation of LTT martensite steels and optimization of additive manufacturing process conditions are identified.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Investigation on the Surface Vortex Formation During Mechanical Stirring with an Axial-Flow Impeller Used in an Aluminum Process

The present study investigated the mechanism of surface vortex formation in an aluminum melt vessel stirred by an axial-flow impeller mechanically. The oxide film is formed at the aluminum melt/air interface, and the movement of the interface entrains the oxide film and inclusions. Hence, the transient movement of melt–air interface is significant. The present study conducted a water model experiment and numerical simulation focusing on the movement of gas–liquid interface. The present study found that the oxide film can be entrained by two phenomena: (1) local surface vortex and (2) sloshing near the vessel wall. The local surface vortex is formed due to the pressure distribution around the impeller, and the sloshing is caused by macroinstabilities, which is generated by the discharged flow of axial-flow impeller. Besides, the shape of gas–liquid interface is dependent on the impeller shape. The axial-flow impeller gives rise to steeply curved shape of gas–liquid interface near the impeller shaft.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Nb Content on Microstructures and Mechanical Properties of Ti-xNb-2Fe Alloys

β-Type Ti-Nb-based alloys exhibit satisfactory biocompatibility and low Young’s modulus for biomedical applications. The microstructure and mechanical properties of a series of Ti-(14, 16, 18, 20, 22, 24)Nb-2Fe alloys fabricated by arc melting were investigated by XRD, optical microscopy, and tensile tests. Both ω and α″ phases existed in the Ti-14Nb-2Fe alloy, while just a single β phase existed in the other alloys. Twinning is an important deformation mechanism that causes work hardening and twinning-induced plasticity. It was found in the Ti-(14, 16, 18, 20)Nb-2Fe alloys and not in the Ti-22Nb-2Fe alloy. The Ti-14Nb-2Fe alloy exhibited the highest tensile strength and the highest Young’s modulus owing to the existence of the ω phase. The tensile strength decreased gradually from 830 MPa (highest) for the Ti-14Nb-2Fe alloy to 540 MPa (lowest) for the Ti-24Nb-2Fe alloy with an increase in the Nb content. The Young’s modulus decreased from 90 GPa for the Ti-14Nb-2Fe alloy to 63 GPa for the Ti-22Nb-2Fe alloy and then increased to 71 GPa for the Ti-24Nb-2Fe alloy. Elongation shows the same trend as the Young’s modulus. The Ti-22Nb-2Fe alloy, with a low Young’s modulus of 63 GPa, tensile strength of 570 MPa, and 15% elongation, was found suitable for biomedical applications. The Ti-20Nb-2Fe alloy also exhibits a high tensile strength, a Young’s modulus ratio of 9.24 × 10{sup −3}, and 18% elongation and is thus considered another valuable Ti alloy for biomedical applications.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Heat Treatment on Microstructure and Mechanical Properties of Ti-6Al-4V-1.5Mn Fabricated by Powder Metallurgy

Ti-6Al-4V-1.5Mn alloy was prepared by powder metallurgy and solid solution aging treatment. Effect of composition segregation on properties of the titanium alloy was eliminated, and microstructure and the mechanical properties of the alloy were studied. Results show that the microstructure of Ti-6Al-4V-1.5Mn is composed of homogeneous α + β phase, and the optimal mechanical properties of the alloy are obtained when the solution temperature is 950 °C and the aging temperature is 460 °C. Analysis of the fracture illustrates that a small amount of dimple was found in the section and the fracture of the material was quasi-cleavage fracture.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Influence of FSW Repairing Process on the Microstructures and Mechanical Properties of Friction Stir-Welded 6082Al Alloy

When two 42-mm 6082Al plates were welded by friction stir welding (FSW), a discontinuously distributing groove defect is formed on the surface of the joint. Subsequently, the FSW repairing process was conducted at the defect location. The influence of the repairing process on the microstructures and mechanical properties of the joints were studied, and a description of the softening mechanism of the repaired joints is provided. The results show that TMAZ at the advance side is the weakest zone of the as-welded joints. The repairing process increases the heat input into the joints and thus promotes the coarsening and transformation of the precipitates in the joints, which further weakens the repaired joints. The average tensile strength of the joints repaired with a 24-mm pin is 205 MPa, which is 91% of that of the as-welded joint. The tensile strength generally increases when the size of the repaired pin decreases. The average tensile strength of the joints repaired with an 8-mm pin is 220 MPa, which is equivalent to the initial joints.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Influence of Austenitizing Temperature on the Microstructure and Mechanical Properties of an Fe-Cr-Ni-Mo-Ti Maraging Stainless Steel

The influence of austenitizing temperature on the microstructure and mechanical properties of an Fe-Cr-Ni-Mo-Ti maraging stainless steel was investigated. The grain size, Laves phase, and retained austenite in steels given different solution treatments were observed using optical microscopy, scanning electron microscopy, and x-ray diffraction. Relationships with mechanical properties were measured by tensile testing. The grain growth rate was relatively slow at temperatures of 800-1000 °C then rapidly increased at higher temperatures. Low-temperature austenitization augmented the retention of austenite, the fraction of which decreased with an increase in austenitizing temperature. The Laves phases, which precipitated in austenite during austenitization at 800-900 °C, were preserved after quenching. The solution treatment had a significant effect on the final tensile properties of the steel after aging, due to the presence of retained austenite and Laves phase reducing its strength.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effects of Sintering Temperature on the Porosity and Mechanical Behavior of Porous Titanium Scaffolds Prepared by Freeze-Casting

The purpose of this study was to investigate the effects of sintering temperature on the microstructure, and associated mechanical properties of porous titanium scaffolds prepared by freeze-casting. Sintering temperature significantly influenced the porosity and the mechanical properties of the titanium scaffolds. The porosity decreased from 60 to 20% as the sintering temperatures increased from 800 to 1100 °C. The scaffolds were of an open pore structure with pore sizes ranging from 2 to 20 μm. The average wall thickness of the porous titanium was measured, using a micro-computed tomography, to be in the range from 9.2 to 26.2 μm. Elastic modulus was between 2 to 7 GPa, depending on vacuum annealing conditions. The compression strength of the scaffolds may exceed 1000 MPa as the sintering temperature higher than 1000 °C. The increase in titanium strength and stuffiness could be mainly attributed to the decrease in porosity as well as the increase in wall thickness.

36 MATERIALS SCIENCE↗