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At least 1,369 records · Page 76

UV-black rutile TiO{sub 2}: An antireflective photocatalytic nanostructure

This work presents an experimental study on the specific quantitative contributions of antireflective and effective surface areas on the photocatalytic and antibacterial properties of rutile TiO{sub 2} nanospikes. They are studied when continuously distributed over the whole surface and when integrated into well-defined microstructures. The nanospikes were produced following MeV ion beam irradiation of bulk rutile TiO{sub 2} single crystals and subsequent chemical etching. The ion beam irradiation generated embedded isolated crystalline nanoparticles inside an etchable amorphous TiO{sub 2} layer, and nanospikes fixed to the not etchable TiO{sub 2} bulk substrate. The produced nanospikes are shown to resist towards aggressive chemical environments and act as an efficient UV antireflective surface. The photocatalytic activity experiments were performed under the ISO 10678:2010 protocol. The photonic and quantum efficiency are reported for the studied samples. The combined micro- and nanostructured surface triples the photonic efficiency compared to the initial flat surface. Results also revealed that the antireflective effect, due to the nanostructuring, is the dominating factor compared to the increase of surface area, for the observed photocatalytic response. The obtained results may be taken as a general strategy to design and precisely evaluate photoactive nanostructures.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

Design Optimization of Liquid Fueled High Velocity Oxy- Fuel Thermal Spraying Technique for Durable Coating for Fossil Power Systems

High-velocity oxy–fuel (HVOF) thermal spraying was developed in 1930 and has been commercially available for twenty-five years. HVOF thermal spraying has several benefits over the more conventional plasma spray technique including a faster deposition rate which leads to quicker turn-around, with more durable coatings and higher bond strength, hardness and wear resistance due to a homogeneous distribution of the sprayed particles. HVOF thermal spraying is frequently used in engineering to deposit cermets, metallic alloys, composites and polymers, to enhance product life and performance. HVOF thermal spraying system is a highly promising technique for applying durable coatings on structural materials for corrosive and high temperature environments in advanced ultra-supercritical coal- fired (AUSC) boilers, steam turbines and gas turbines. HVOF thermal spraying is the preferred method for producing coatings with low porosity and high adhesion. HVOF thermal spray process has been shown to be one of the most efficient techniques to deposit high performance coatings at moderate cost. Variables affecting the deposit formation and coating properties include hardware characteristics such as nozzle geometry and spraying distance and process parameters such as equivalence ratio, gas flow density, and powder feedstock. In the spray process, the powder particles experience very high speeds combined with fast heating to the powder material melting point or above. This high temperature causes evaporation of the powder, dissolution, and phase transformations. Due to the complex nature of the HVOF technique, the control and optimization of the process is difficult. In general, good coating quality with suitable properties and required performance for specific applications is the goal in producing thermal spray coatings. In order to reach this goal, a deeper understanding of the spray process as a whole is needed. Although many researchers studied commercial HVOF thermal spray systems, there exists a lack of fundamental understanding of the effect of hardware characteristics and operating parameters on HVOF thermally sprayed coatings. Motivated by these issues, this study is devoted to investigate the effect of hardware characteristics (e.g. spraying distance) and operating parameters (e.g. combustion chamber pressure, equivalence ratio, and total gas flow rate) on HVOF sprayed coatings using Inconel 718 alloy. The current study provides extensive understanding of several key operating and process parameters to optimize the next generation of HVOF thermally sprayed coatings for high temperature and harsh environment applications. A facility was developed to support this endeavor in a safe and efficient way, including a HVOF thermal spray system with a Data Acquisition and Remote Controls system (DARCS). The coatings microstructure and morphology were examined using X-Ray Diffraction (XRD), Scanning Electron Microscope (SEM) and Nanoindentation.

20 FOSSIL-FUELED POWER PLANTS↗

Target Configuration Effect on Microstructures and Properties of Vertically Aligned Nanocomposites

Vertically aligned nanocomposites (VANs) are unique thin films with vertical nanostructures embedded in a matrix material, allowing for the integration of two distinct materials. These nanocomposites offer novel combined physical properties, such as nanocomposite-based multiferroics and strongly coupled physical properties, such as magneto-optic coupling. Much work has been conducted in exploring different two-phase combinations and various processing conditions to achieve novel tunable properties that cannot be obtained by any single-phase material alone. Here, in this work, the target configuration effects are explored for the growth of LaFeO 3 –CoNi 2 O 4 VANs. Both mixed and pie-shaped targets are utilized to compare the target configuration effects on the phase separation, morphology tuning, and their resulting physical properties, including optical and magnetic properties. This work suggests that the target configuration is another important parameter for achieving the desired VAN morphology and can be used to design different two-phase VANs with tailorable properties.

36 MATERIALS SCIENCE↗

Dilation Behavior of Thermal Spray Coatings

The thermal expansion of a thermally sprayed coating material is an important design-relevant property from both processing and application service points of view. High thermal stresses and residual strains can arise during deposition, and thermal exposure in service. The linkage to process conditions which can impact both physical and chemical attributes of the microstructure and consequently its expansion behavior is of great importance. The observed dilation response of various coatings is discussed based on the processing effects that induce differences in microstructural features and the impact of residual strain and annealing of defects on the dilation behavior during first thermal exposure. The coefficient of thermal expansion (CTE) of coatings was found to approach the bulk when the material is not sensitive to oxidation in-flight. For those materials sensitive to oxidation, mathematical models used to describe effective properties of composite materials were adopted to describe the CTE property. A large irreversible dilation change was found in the first heating cycle due to defect annealing (referred to as thermal shakedown). Several reasons are hypothesized for the magnitude of such dilation change. Finally, together, the paper presents a comprehensive analysis of thermal expansion behavior of a diversity of thermal spray processed materials.

36 MATERIALS SCIENCE↗

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↗

Radiation Tolerance and Mechanical Properties of Nanostructured Amorphous-Ceramic/Metal Composites

The objective of this work was to use a radically non-traditional approach to design amorphous-ceramic/metal composites for service in extreme irradiation environments. The project was built on a strong integration among four research teams for materials synthesis and characterization, ion irradiation, mechanical evaluation, and atomic scale modeling. Rather than try to prevent microstructure changes in polycrystalline aggregates, the research team worked to evolve composite systems where one of the constituents is intentionally synthesized in a non-crystalline or “amorphous” state. Because amorphous materials possess no translational symmetry, such alloys do not contain conventional crystal defects such as vacancies, interstitials, or dislocations. These materials offer the possibility of eliminating the root cause responsible for radiation damage in polycrystalline solids - namely the production of point defects and clusters thereof in collision cascades - and could serve as the basis for developing a new class of structural materials with unprecedented resistance to radiation. The amorphous alloys were used to develop advanced amorphous-ceramic/metal composites with greatly improved radiation tolerance and stability above 500oC, and improved mechanical performance by combining the good properties of amorphous materials (high strength and elastic limit) with those of crystalline materials (high toughness, strain hardening). The ceramic component of the composite consisted of a high crystallization temperature and radiation tolerant amorphous alloy composed of Si-O-C, silicon oxycarbide, while the metal layer was Fe and Fe(Cr), chosen to serve as model materials for steel. A prime hypothesis that drove this work is that the composite interface, together with the composite constituents, would provide significantly enhanced radiation tolerance, similar to or superior to those observed in metallic nanolayered structures, in a more engineering relevant material system. As our experimental data and modeling show, we have successfully developed a new class of ceramic/metal composites that can be adapted for engineering applications, thus significantly impacting improved materials performance for advanced nuclear reactors.

36 MATERIALS SCIENCE↗

LightMAT - Pediction of Aluminum/Steel Joint Failure

Develop a predictive model of dissimilar metallic spot joints and their behavior during fracture; specifically, whether the joint fractures via interfacial fracture or button pull-out as a function of alloy, sheet thickness, faying interface microstructure, and thermal-mechanical treatment of the weld nugget and heat affected zone. Having the ability to model whether a given joint structure would fracture inter-facially or via button pullout will reduce development time and provide savings to vehicle design programs. This would provide a significant step function improvement in reducing the time-to-market for this multi-material, weight-saving technology.

36 MATERIALS SCIENCE↗

Characterization of Electron Beam Free-Form Fabricated 2219 Aluminum and 316 Stainless Steel

Researchers at NASA Langley Research Center have developed an additive manufacturing technology for ground and future space based applications. The electron beam free form fabrication (EBF3) is a rapid metal fabrication process that utilizes an electron beam gun in a vacuum environment to replicate a CAD drawing of a part. The electron beam gun creates a molten pool on a metal substrate, and translates with respect to the substrate to deposit metal in designated regions through a layer additive process. Prior to demonstration and certification of a final EBF3 part for space flight, it is imperative to conduct a series of materials validation and verification tests on the ground in order to evaluate mechanical and microstructural properties of the EBF3 manufactured parts. Part geometries of EBF3 2219 aluminum and 316 stainless steel specimens were metallographically inspected, and tested for strength, fatigue crack growth, and fracture toughness. Upon comparing the results to conventionally welded material, 2219 aluminum in the as fabricated condition demonstrated a 30% and 16% decrease in fracture toughness and ductility, respectively. The strength properties of the 316 stainless steel material in the as deposited condition were comparable to annealed stainless steel alloys. Future fatigue crack growth tests will integrate various stress ranges and maximum to minimum stress ratios needed to fully characterize EBF3 manufactured specimens.

Ekrami, Yasamin↗

Casting Aluminum Alloys: Their Physical and Mechanical Metallurgy

The follow up to the fall 2007 work on the structure, properties, thermal resistance, corrosion and fatigue of aluminum alloys in industrial manufacturing, discusses findings from the past decade, including sections on new casting alloys, novel casting technologies, and new methods of alloys design. The book also includes other hot topics, such as the implementation of computational technologies for the calculation of phase equilibria and thermodynamic properties of alloys, the development of software for calculation of diffusion processes in aluminum alloys, computational modeling of solidification microstructure and texture evolution of multi-component aluminum materials.

36 MATERIALS SCIENCE↗

Japan-US Joint Research Project PHENIX (2013–2018); Heat Transfer Tests, Neutron Irradiation and Post-Irradiation Examinations for Development of He-Cooled Tungsten Divertor

The goal of the Japan-US joint research project PHENIX (2013–2018) is to understand the feasibility of He-cooled W divertor for DEMO applications. To achieve this goal, the project has three major objectives: (1) to understand heat transfer in a divertor module cooled with high-temperature and high-pressure He gas, (2) to establish database on thermomechanical properties of W materials after high temperature (~500, ~800 and ~1100 °C) neutron irradiation with fusion-relevant energy spectrum, and (3) to clarify tritium (T) trapping and permeation in neutron-irradiated W materials. Heat transfer tests for a He-cooled modular divertor with multi-jet (HEMJ) have been performed, and the problem of heat transfer degradation by re-laminarization was identified.The irradiation capsule with thermal neutron shielding was designed for high temperature neutron irradiation in the High Flux Isotope Reactor (HFIR), Oak Ridge National Laboratory (ORNL) with fusion-relevant transmutation. The expected damage level is 1–1.5 displacements per atom (dpa). Heat load resistance, thermal conductivity, mechanical properties and microstructures are examined in ORNL after the irradiation. Mechanical properties of W single crystal samples irradiated with neutrons in HFIR at 90– 850 °C without thermal neutron shielding were examined for comparison. Significant hardening was observed after irradiation to >1 dpa. Microstructural examinations revealed that the hardening was mainly caused by formation of irradiation-induced precipitates consisting of W, Re and Os. Comparison with new samples irradiated in the capsule with thermal neutron shielding will show the effects of irradiation temperatures and transmutation elements. Retention and permeation of hydrogen isotopes including T in neutron-irradiated samples are examined in Idaho National Laboratory, and permeation of H and D in samples damaged with surrogate irradiations (heavy ions, electrons, etc.) is measured in Sandia National Laboratories, Livermore, to study hydrogen-defect interactions in wider conditions. The measurement of D retention in the single crystal W sample after neutron irradiation to 0.1 dpa at 360 °C and subsequent plasma exposure at 400 °C showed significant trapping effects by radiation-induced defects.

Ueda, Yoshio↗

Code Qualification of Structural Materials for AFCI Advanced Recycling Reactors

This report summarizes the further findings from the assessments of current status and future needs in code qualification and licensing of reference structural materials and new advanced alloys for advanced recycling reactors (ARRs) in support of Advanced Fuel Cycle Initiative (AFCI). The work is a combined effort between Argonne National Laboratory (ANL) and Oak Ridge National Laboratory (ORNL) with ANL as the technical lead, as part of Advanced Structural Materials Program for AFCI Reactor Campaign. The report is the second deliverable in FY08 (M505011401) under the work package 'Advanced Materials Code Qualification'. The overall objective of the Advanced Materials Code Qualification project is to evaluate key requirements for the ASME Code qualification and the Nuclear Regulatory Commission (NRC) approval of structural materials in support of the design and licensing of the ARR. Advanced materials are a critical element in the development of sodium reactor technologies. Enhanced materials performance not only improves safety margins and provides design flexibility, but also is essential for the economics of future advanced sodium reactors. Code qualification and licensing of advanced materials are prominent needs for developing and implementing advanced sodium reactor technologies. Nuclear structural component design in the U.S. must comply with the ASME Boiler and Pressure Vessel Code Section III (Rules for Construction of Nuclear Facility Components) and the NRC grants the operational license. As the ARR will operate at higher temperatures than the current light water reactors (LWRs), the design of elevated-temperature components must comply with ASME Subsection NH (Class 1 Components in Elevated Temperature Service). However, the NRC has not approved the use of Subsection NH for reactor components, and this puts additional burdens on materials qualification of the ARR. In the past licensing review for the Clinch River Breeder Reactor Project (CRBRP) and the Power Reactor Innovative Small Module (PRISM), the NRC/Advisory Committee on Reactor Safeguards (ACRS) raised numerous safety-related issues regarding elevated-temperature structural integrity criteria. Most of these issues remained unresolved today. These critical licensing reviews provide a basis for the evaluation of underlying technical issues for future advanced sodium-cooled reactors. Major materials performance issues and high temperature design methodology issues pertinent to the ARR are addressed in the report. The report is organized as follows: the ARR reference design concepts proposed by the Argonne National Laboratory and four industrial consortia were reviewed first, followed by a summary of the major code qualification and licensing issues for the ARR structural materials. The available database is presented for the ASME Code-qualified structural alloys (e.g. 304, 316 stainless steels, 2.25Cr-1Mo, and mod.9Cr-1Mo), including physical properties, tensile properties, impact properties and fracture toughness, creep, fatigue, creep-fatigue interaction, microstructural stability during long-term thermal aging, material degradation in sodium environments and effects of neutron irradiation for both base metals and weld metals. An assessment of modified versions of Type 316 SS, i.e. Type 316LN and its Japanese version, 316FR, was conducted to provide a perspective for codification of 316LN or 316FR in Subsection NH. Current status and data availability of four new advanced alloys, i.e. NF616, NF616+TMT, NF709, and HT-UPS, are also addressed to identify the R&D needs for their code qualification for ARR applications. For both conventional and new alloys, issues related to high temperature design methodology are described to address the needs for improvements for the ARR design and licensing. Assessments have shown that there are significant data gaps for the full qualification and licensing of the ARR structural materials. Development and evaluation of structural materials require a variety of experimental facilities that have been seriously degraded in the past. The availability and additional needs for the key experimental facilities are summarized at the end of the report. Detailed information covered in each Chapter is given.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Disk Alloy Development

The advanced powder metallurgy disk alloy ME3 was designed using statistical screening and optimization of composition and processing variables in the NASA HSR/EPM disk program to have extended durability at 1150 to 1250 "Fin large disks. Scaled-up disks of this alloy were produced at the conclusion of this program to demonstrate these properties in realistic disk shapes. The objective of the UEET disk program was to assess the mechanical properties of these ME3 disks as functions of temperature, in order to estimate the maximum temperature capabilities of this advanced alloy. Scaled-up disks processed in the HSR/EPM Compressor / Turbine Disk program were sectioned, machined into specimens, and tested in tensile, creep, fatigue, and fatigue crack growth tests by NASA Glenn Research Center, in cooperation with General Electric Engine Company and Pratt & Whitney Aircraft Engines. Additional sub-scale disks and blanks were processed and tested to explore the effects of several processing variations on mechanical properties. Scaled-up disks of an advanced regional disk alloy, Alloy 10, were used to evaluate dual microstructure heat treatments. This allowed demonstration of an improved balance of properties in disks with higher strength and fatigue resistance in the bores and higher creep and dwell fatigue crack growth resistance in the rims. Results indicate the baseline ME3 alloy and process has 1300 to 1350 O F temperature capabilities, dependent on detailed disk and engine design property requirements. Chemistry and process enhancements show promise for further increasing temperature capabilities.

Gabb, Tim↗

Non-Solvent Induced Phase Separation Enables Designer Redox Flow Battery Electrodes

Porous carbonaceous electrodes are performance-defining components in redox flow batteries (RFBs), where their properties impact the efficiency, cost, and durability of the system. The overarching challenge is to simultaneously fulfill multiple seemingly contradictory requirements—i.e., high surface area, low pressure drop, and facile mass transport—without sacrificing scalability or manufacturability. Here, non-solvent induced phase separation (NIPS) is proposed as a versatile method to synthesize tunable porous structures suitable for use as RFB electrodes. The variation of the relative concentration of scaffold-forming polyacrylonitrile to pore-forming poly(vinylpyrrolidone) is demonstrated to result in electrodes with distinct microstructure and porosity. Tomographic microscopy, porosimetry, and spectroscopy are used to characterize the 3D structure and surface chemistry. Flow cell studies with two common redox species (i.e., all-vanadium and Fe2+/3+) reveal that the novel electrodes can outperform traditional carbon fiber electrodes. It is posited that the bimodal porous structure, with interconnected large (>50 µm) macrovoids in the through-plane direction and smaller (<5 µm) pores throughout, provides a favorable balance between offsetting traits. Although nascent, the NIPS synthesis approach has the potential to serve as a technology platform for the development of porous electrodes specifically designed to enable electrochemical flow technologies.

36 MATERIALS SCIENCE↗

Fission gas bubble identification using MATLAB's image processing toolbox

Automated image processing routines have the potential to aid in the fuel performance evaluation process by eliminating bias in human judgment that may vary from person-to-person or sample-to-sample. This study presents several MATLAB based image analysis routines designed for fission gas void identification in post-irradiation examination of uranium molybdenum (U–Mo) monolithic-type plate fuels. Frequency domain filtration, enlisted as a pre-processing technique, can eliminate artifacts from the image without compromising the critical features of interest. This process is coupled with a bilateral filter, an edge-preserving noise removal technique aimed at preparing the image for optimal segmentation. Adaptive thresholding proved to be the most consistent gray-level feature segmentation technique for U–Mo fuel microstructures. The Sauvola adaptive threshold technique segments the image based on histogram weighting factors in stable contrast regions and local statistics in variable contrast regions. Once all processing is complete, the algorithm outputs the total fission gas void count, the mean void size, and the average porosity. The final results demonstrate an ability to extract fission gas void morphological data faster, more consistently, and at least as accurately as manual segmentation methods. - Highlights: •Automated image processing can aid in the fuel qualification process. •Routines are developed to characterize fission gas bubbles in irradiated U–Mo fuel. •Frequency domain filtration effectively eliminates FIB curtaining artifacts. •Adaptive thresholding proved to be the most accurate segmentation method. •The techniques established are ready to be applied to large scale data extraction testing.

36 MATERIALS SCIENCE↗

Weld Quality Assessment in Fiber Laser Weldments of Ti-6Al-4V Alloy

Laser welding experiments are performed on Ti-6Al-4V alloy sheets by adopting fiber laser. A special kind of workpiece fixture is designed and fabricated for providing shielding gas. After experiments, penetration depth, fusion zone width and heat-affected zone size at different locations within weld bead are measured and discussed in detail. Influence of line energies on the formation of non-uniform microstructure within weld bead is explored by conducting microstructural analysis. Various kinds of microstructural morphology of martensitic structure such as α′ martensite, blocky α, massive α and basket-weave microstructure are found in fusion zone. Experimentally, it is found that beam power is the key parameter for controlling penetration depth. Higher hardness is noticed within fusion zone due to the existence of large volume of α′ martensite. Tensile strength and hardness of welded specimens are increased with decreasing line energy. Small amount of micropores are also found in solidified weld bead. However, its sizes are in acceptable range as per BSEN:4678 standard. Most favorable welding condition is identified as a combination of beam power of 800 W and welding speed of 1000 mm/min which yields full penetration, narrower bead width, small heat-affected zone, minimal defects and acceptable mechanical properties.

36 MATERIALS SCIENCE↗

Text Mining for Process–Structure–Properties Relationships in Metals

With the advent of large language models (LLMs), the vast unstructured text within millions of academic papers is increasingly accessible for materials discovery—although significant challenges remain. While LLMs offer promising few- and zero-shot learning capabilities, particularly valuable in the materials domain where expert annotations are scarce, general-purpose LLMs often fail to address key materials-specific queries without further adaptation. To bridge this gap, fine-tuning LLMs on human-labeled data is essential for effective structured knowledge extraction (Liu in The Importance of Human-Labeled Data in the Era of LLMs, 2023). Here, in this study, we introduce a novel annotation schema designed to extract generic process–structure–properties relationships from scientific literature. We demonstrate the utility of this approach using a dataset of 128 abstracts, with annotations drawn from two distinct domains: high-temperature materials (Domain I) and uncertainty quantification in simulating materials microstructure (Domain II). Initially, we developed a conditional random field (CRF) model based on MatBERT—a domain-specific BERT variant—and evaluated its performance on Domain I. Subsequently, we compared this model with a fine-tuned LLM (GPT-4o from OpenAI) under identical conditions. Our results indicate that fine-tuning LLMs can significantly improve entity extraction performance over the BERT-CRF baseline on Domain I. However, when additional examples from Domain II were incorporated, the performance of the BERT-CRF model became comparable to that of the GPT-4o model. These findings underscore the potential of our schema for structured knowledge extraction and highlight the complementary strengths of both modeling approaches.

Materials science↗

Accelerated creep profiling: a high-throughput thermal- and stress-gradient approach applied to additive and wrought stainless steel

Here, this study investigates logarithmic creep behavior at temperatures near room temperature in wrought and additively manufactured (AM) 316 L austenitic stainless steel. A novel high-throughput (HiTp) methodology employed thermal gradients to obtain stress- and temperature-dependence of creep behavior. The findings, based on 104 two-week creep tests, reveal significant differences in creep response between wrought and AM materials. Compared to the wrought material, the AM material exhibited a higher activation energy and a lower activation volume. These differences were attributed to the materials’ distinct microstructural features, e.g., dislocation cell structures and precipitate distributions, which alter the susceptibility to dislocation glide creep, particularly at stresses below the yield stress. The HiTp methodology provides both an accelerated determination of low-temperature creep mechanisms, offering critical data for the design and optimization of alloys in near-ambient, high stress applications.

316 L Stainless steel↗