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At least 1,405 records · Page 78
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DOE OSTI2017

Influence of Temperature on the Texture Distribution in Two-Phase Region Hot Deformation of Grain-Oriented Silicon Steel

Hot deformation simulation test of 3% Si grain-oriented silicon (CGO) steel was carried out at different temperatures, and evolution of microstructures and recrystallized textures in two-phase region was analyzed by electron backscatter diffraction and optical microscopy. The “δ → γ” and “γ → α” phase transformation points of the two-phase region measured by differential scanning calorimetry method are 1272 and 819 °C, respectively, which are within the ranges of 1300-1350 and 800-850 °C, measured by water quenching. The hot deformation temperature has a large effect on the microstructure and texture in the steel. A higher hot deformation temperature leads to higher degree of recrystallization and larger average grain size, more γ-fiber textures and cube {100} <001> texture, but the rotated cube {100} <011> texture is stable. The recrystallized microstructure was also affected by the phase compositions. While the cube {100} <001> texture results in typical austenite recrystallization texture, {111} textures lead to typical ferrite rolling textures.

36 MATERIALS SCIENCE↗
DOE OSTI2017

The Evolution of the Weld Metal Microstructures in Dissimilar Titanium Welds Based on Al and Mo Equivalents

CO{sub 2} laser welding of Ti-15V-3Cr-3Al-3Sn to Ti-4.5Al-3V-2Fe-2Mo was conducted in the study. The notched fracture and microstructures of the weld metal (WM) with various post-weld aging treatments were studied. In the as-welded sample, the WM comprised only β phase, which was relatively soft and ductile. Moreover, the phase constituent of the as-welded WM was related to the Al and Mo equivalents and further compared with other welds. The microstructural morphologies and microhardness of the WMs of dissimilar welds exhibited significant changes after post-weld aging at distinct temperatures. Increasing the Al equivalent ([Al]{sub EQ}) of the WM caused an increased response to age-hardening during post-weld aging treatments. When the aging temperature was increased from 426 to 593 °C, the α precipitates in the WM grew in size, causing a decrease in hardness, but an improvement in toughness.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Heavy Deformation of Patented Near-Eutectoid Steel

Evolution of microstructure in the patented near-eutectoid steel, forged under varying situations, is critically examined in the present investigation. Steel with 0.74 wt.% carbon is isothermally annealed at 500 °C to obtain fine pearlite microstructure. Steel samples, so patented, are subjected to mechanical deformation by forging at various temperatures with different amount of thickness reduction. Microstructural analyses have revealed that mechanical deformation by forging at lower temperatures brings about partial dissolution of cementite, which is followed by the formation of ε-carbide in the microstructures. In contrast, cementite is precipitated within ferrite matrix upon warm or hot forging at higher temperatures. It is further observed that increasing deformation percent during low-temperature forging reduces interlamellar spacing of pearlite, whereas an opposite trend is noticed in case of deformation at higher temperature; moreover, deformation induced the change in interlamellar spacing and formation of fine carbide phases in microstructures has caused appreciable enhancement in hardness of the steel.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Recrystallization Behavior and Super-Elasticity of a Metastable β-Type Ti-21Nb-7Mo-4Sn Alloy During Cold Rolling and Annealing

Based on the d-electron alloy design theory, a new metastable β-type titanium alloy for biomedical applications, Ti-21Nb-7Mo-4Sn (wt.%) was designed in this article. This theory predicted this alloy was a metastable single β-type titanium alloy with low elastic modulus at room temperature, and the β-phase transition (β to α″) would be easy to occur during the cold rolling. The evolution of microstructure and mechanical properties of this alloy during cold rolling plus annealing were investigated by means of x-ray diffraction, optical microscope, transmission electron microscope and mechanical properties test. The results indicate that only β phase can be identified in this alloy before cold rolling, while a large amount of lath martensite (α″ phase) appears after cold rolling due to stress-induced martensitic transformation, which is in accordance with the prediction of the d-electron alloy design theory. The recrystallization nucleation occurs preferentially in the martensite lath region during the subsequent annealing process, and this region forms a large number of nano-crystals and microcrystals, showing that cold rolling plus annealing can become a new process for refining grains. Compared with casting and cold rolling samples, the annealing materials at 923 K for 10 min have excellent comprehensive mechanical properties with lower elastic modulus (58 GPa) and higher elastic recovery rate (35.39%).

36 MATERIALS SCIENCE↗
DOE OSTI2019

Workability Characteristics and Deformation Mechanisms of Die-Cast AM60 and AZ91 Magnesium Alloys: Correlation with Processing Maps

Thermo-mechanical deformation behavior of the die-cast AM60 and AZ91 alloys was assessed by performing uniaxial compression tests on Gleeble 3800 simulator under different temperatures and strain rate conditions. Low-temperature deformation behavior of both alloys was accessed at 25, 100, and 150 °C, at the strain rates of 0.1 and 1 s{sup −1}. Processing maps at a true strain of 0.5 were generated to study the intrinsic hot workability of AM60 and AZ91 alloys. Optimum processing windows were identified, and the evolution of microstructures and textures was correlated with the imposed deformation conditions. The processing map for the AM60 alloy exhibited three dynamic recrystallization (DRX) domains in the ranges: (1) 320-400 °C and 0.2-1.5 s{sup −1}, (1A) 300-325 °C and 0.1-0.2 s{sup −1}, and (2) 360-400 °C and 3-5 s{sup −1}. In Domain 1, DRX occurred predominantly by pyramidal slip and recovery mechanisms by cross-slip as confirmed by the randomized textures. Deformation in Domain 1A is by the combination of basal and prismatic slip. In Domain 2, dynamic recovery was a softening mechanism controlled by the climb. The processing map for AZ91 alloy exhibited two DRX domains in the ranges: (1) 260-310 °C and 0.1-0.5 s{sup −1} and (2) 325-350 °C and 0.8-3 s{sup −1}. The rate-controlling mechanism was climb by lattice self-diffusion in Domain 1 and by grain boundary self-diffusion in Domain 2. Both alloys exhibited flow instability at 200 and 250 °C, and therefore, they were unsuitable for processing at these temperatures.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Correlation Between Structure and Properties of Low-Carbon Cu-Ni-Mo-Ti-Nb Ultrahigh-Strength Steel

Low-carbon Cu-Ni-Mo-Ti-Nb steel having more than 1700 MPa tensile strength and good low-temperature impact toughness was successfully designed and processed for automobile, defence and structural applications. The steel was thermomechanical controlled processed at a different finish rolling temperatures (750-850 °C) and cooled at two different conditions: air cooling and water quenching. Evolutions of microstructure and precipitates were thoroughly characterised to understand the effect of different factors, such as steel composition, finish rolling temperature and cooling rate on the mechanical properties. The results indicate that the steel processed at 750 °C finish rolling temperature (FRT) followed by water quenching has exhibited superior tensile properties with a yield strength of 1034-1449 MPa, the tensile strength of 1598-1726 MPa and total elongation of 10-13%. Such an ultrahigh-strength level is primarily attributed to the combined effect of lower bainite dominated microstructure along with precipitation hardening. The satisfactory low-temperature toughness is promoted by low finish rolling temperature and higher amount of misorientation offered by the boundaries within the lower bainite.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Understanding the Mechanism of Dynamic Recrystallization During High-Temperature Deformation in Nb-1Zr-0.1C Alloy

In the present investigation, a systematic study of the evolution of microstructure and crystallographic texture during hot deformation of Nb-1Zr-0.1C was carried out in the temperature range 1773-1973 K (1500-1700 °C) at different strain rates of 0.001, 0.01 and 0.1 s{sup −1}. The aim was to examine the mechanisms of dynamic recovery and recrystallization in a high-temperature range. A detailed microstructural analysis of the deformed samples was performed using the electron backscatter diffraction technique to study the occurrence and nature of various dynamic restoration processes; the different regimes of dynamic recovery and recrystallization were identified. The orientations of the dynamically recrystallized grains were found to be (001) .

36 MATERIALS SCIENCE↗
DOE OSTI2024

Effects of Post-sintering Annealing on (NdLa)-(FeCo)-B Magnets

A common limitation of La substitutions into (Nd, La) 2 Fe 14 B magnets is the reduction of the anisotropy field (H a ), which decreases magnet coercivity (H cj ). In this study, adding a small amount of Pr-Cu to a La-containing neo magnet may modify the grain boundary (GB), which can help recover a fraction of the degraded H cj . An optimal GB modification requires a carefully designed post-sinter heat treatment, which is the focus of this work on characterizing the effects of multi-step post-sintering annealing on the evolutions of microstructure and magnetic properties. We find that Nd and Cu concentrations at GBs and triple junctions (TJs) increase when the annealing temperatures are lowered. Annealing temperatures of 580°C and 480°C (near rare-earth-rich eutectic temperatures) enabled the development of a thick and continuous GB phase, which helps to magnetically decouple the grains, and, thus, enhance H cj . For the alloy with 25% Nd replaced by La, and with the addition of 7.5 wt.% of Pr 68 Cu 32 as GB modifier, the optimized multi-step post-sinter annealing improved the H cj from 4.8 kOe to 9 kOe.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Dynamic Uniaxial Compression of HSLA-65 Steel at Elevated Temperatures

Here, the dynamic response of a high-strength, low alloy Grade 65 (HSLA-65) steel, used by the United States Navy for ship hull construction, is investigated under dynamic uniaxial compression at temperatures ranging from room temperature to 1000 °C using a novel elevated temperature split-Hopkinson pressure bar. These experiments are designed to probe the dynamic response of HSLA-65 steel in its single α-ferrite phase, mixed α + γ-austenite phase, and the single γ-austenite phase, as a function of temperature. The investigation is conducted at two different average strain rates—1450 and 2100/s. The experimental results indicate that at test temperatures in the range from room temperature to lower than 600 °C, i.e. prior to the development of the mixed α + γ phase, a net softening in flow strength is observed at all levels of plastic strain with increase in test temperatures. As the test temperatures are increased, the rate of this strain softening with temperature is observed to decrease, and at 600 °C the trend reverses itself resulting in an increase in flow stress at all strains tested. This increase in flow stress is understood be due to dynamic strain aging, where solute atoms play a distinctive role in hindering dislocation motion. At 800 °C, a (sharp) drop in the flow stress, equivalent to one-half of its value at room temperature, is observed. As the test temperature are increased to 900 and 1000 °C, further drop in flow stress are observed at all plastic strain levels. In addition, strain hardening in flow stress is observed at all test temperatures up to 600 °C; beyond 800 °C the rate of strain hardening isobserved to decrease, with strain softening becoming dominant at temperatures of 900 °C and higher. Moreover, comparing the high strain rate stress versus strain data gathered on HSLA 65 in the current investigation with those available in the literature at quasi-static strain rates, strain-rate hardening can be inferred. The flow stress increases from 700 MPa at 8 × 10 -4 /s to 950 MPa at 1450/s and then to 1000 MPa at 2100/s at a strain of 0.1. Finally, optical microscopy is used to understand evolution of microstructure in the posttest samples at the various test temperatures employed in the present study.

36 MATERIALS SCIENCE↗
DOE OSTI2017

The formation and characterization of large twin related domains

The enhanced properties of grain boundary engineered metals are a result of their unique microstructures, which contain large clusters of twinned grains, called twin related domains. These large twin related domains in grain boundary engineered Ni were found to form through recrystallization. Orientation mapping showed that sparse nucleation and multiple twinning resulted in twin related domains containing hundreds of grains connected together in complex morphologies. A correlation was found between the size of the twin related domains and the overall twin boundary fraction. The same correlation was also observed in Cu and a Ni superalloy, showing that this is a general observation for grain boundary engineered microstructures. This finding can be understood through the topology of the twin related domains and an accompanying scaling relation is provided. The crystal orientations contained within each twin related domain were observed to depend on both the spatial correlation of twinning variants and the degree of branching in the twin boundary network. The results suggest a natural way of quantifying grain boundary engineered microstructures and provide a step toward making a closer connection between processing, microstructure, and performance.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Revealing the effect of local stresses on twin growth mechanisms in titanium using synchrotron X-ray diffraction

Deformation twinning has a significant impact on the evolution of microstructure and mechanical response in hexagonal close packed (hcp) metals. Understanding the physical mechanisms associated with twin nucleation and growth processes is important to enable the broad use of hcp metals. While both nucleation and growth are conditioned by the local stress state, few studies have quantified it in bulk deformed samples. In this study, we reveal the effects of local stresses on twin thickening using in-situ synchrotron experiments with differential aperture X-ray microscopy. High purity Ti is deformed under four-point bending to activate {1012} tensile twins. Further, 3D stress fields with a spatial resolution of 0.5μm are mapped in the vicinity of low and high macroscopic Schmid factor (MSF) twins growing inside a grain. Reconciling this experimental analysis with recent twin growth models reveals that the growth of low MSF twins is limited by the nucleation of twin growth defects in the high-purity Ti sample. While growth-inducing defect nucleation may occur in many places on the interface of the high resolved shear stress (RSS)/MSF twin, the nucleation rate of twinning disconnections for the low MSF twin is high only at the end of the twin near a stress concentration. Once nucleated, these defects easily propagate into lower RSS regions of the grain resulting in twin growth. This work highlights the importance of stress concentrations not only for twin (embryo) nucleation, but also to the growth process of twins, particularly in low MSF twins.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Local chemical ordering of a neutron-irradiated CrFeMnNi compositionally complex alloy

While ion-irradiation studies are a critical first step in studying compositionally complex alloys (CCAs) for nuclear applications, they do not capture all the microstructural changes occurring under the low irradiation dose rates and different particles’ scattering patterns experienced in a nuclear reactor setting. To explore these phenomena in reactor-relevant conditions for the first time in CCA, the single-phase solid-solution Cr 10 Fe 30 Mn 30 Ni 30 was neutron irradiated up to 6.61 displacements per atom at 395 and 579 °C. Irradiation-enhanced local chemical ordering (LCO) well beyond the range of short range ordering was observed, and is predicted to be the precursor to the precipitation of a coherent Ni-Mn L1 0 phase and a Cr-rich α’ phase, though TEM analysis did not indicate the presence of either in any irradiation condition. The line density of faulted dislocation loops decreased from 6.47 to 1.69 ∙ 10 15 m -2 from 3.43 to 6.61 dpa at 579 °C despite no appreciable faulted loop content in the unirradiated material. LCO is expected to increase the complexity of the energy landscape within this alloy, restricting interstitial point defect mobility and creating local regions of greater stacking fault energy. These contribute to the negative correlation between irradiation dose and faulted dislocation loop density in this study, as well as the lack of void swelling observed.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Multiscale investigation of thermomechanical and compositional developments in Ni alloy 718 under laser processing

Laser processing has been widely employed in various applications due to its exceptional spatial resolution. However, the rapid temperature gradients generated in localized areas present significant challenges for experimental characterization using conventional instruments. To characterize Ni alloy 718 during laser processing, we employed in-situ synchrotron X-ray diffraction with a high-speed detector, a method particularly well-suited for probing processes with high temporal and spatial resolution. Through a series of in-situ experiments, we investigated the local variations in the evolution of microstructures and thermomechanical behaviors within a keyhole mode melt pool. The in situ macroscopic thermomechanical behaviors were quantified using an empirical model derived from diffraction patterns, with experimental results showing reasonable agreement with finite element analysis. Various laser parameters were tested to assess their influences on the residual strains in the melt pools. The results revealed that the residual strain in the keyhole mode melt pool is relatively insensitive to variations in the parameters and is smaller than that in the melt pool created under conduction mode laser scanning. Additionally, we analyzed the shapes of individual diffraction spots, providing insights into the plastic behaviors and compositional developments in the resolidified alloy. The analysis confirmed that compositional variations in a dendritic microstructure manifest as asymmetric broadening of the diffraction spots.

Ni alloy 718↗
DOE OSTI2025

MX precipitate behavior in an irradiated advanced Fe-9Cr steel: Self-ion irradiation effects on phase stability

In an effort to optimize Fe-9Cr reduced activation ferritic/martensitic (RAFM) steels and to inform the design and operation of fusion reactors, this work represents the first in a series of cohesive studies dedicated to the evolution of MX-TiC precipitates under accelerated single and dual ion irradiations. This study investigates CNA9, a simplified Fe-9Cr RAFM steel featuring initial MX-TiC precipitate densities of (2.3±0.3)×10²¹ m⁻³. This material was subjected to single self-ion irradiation at damage levels ranging from 1 to 100 displacements per atom (dpa) over a temperature range of 300 to 600°C, with a nominal dose rate of 7×10⁻⁴ dpa/s. Irradiation-induced coarsening was observed, as evidenced by statistically significant increases in mean diameter sizes, at 15 dpa at both 500°C and 600°C, whereas no coarsening was noted at 300°C or 400°C. Further, complete dissolution of precipitates occurred at damage levels of 50 and 100 dpa across the two temperatures tested (300°C and 500°C) while no significant changes were observed at any doses below 15 dpa at 500°C. Experimentally parameterized recoil resolution modeling suggests that the observed radiation stability of MX-TiC precipitates is intricately linked to diffusional changes of solutes resulting from the co-evolution of microstructural features within the experiments. The findings align with current theoretical perspectives on radiation-induced precipitate stability in complex alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Applications of CALPHAD modeling and databases in advanced lightweight metallic materials

Here this paper presents an overview on the application of CALPHAD (CALculation of Phase Diagrams) methodology in the design and development of advanced lightweight metallic materials including magnesium, aluminum, titanium, aluminum-based metal matrix composites, and high entropy alloys. In this work, CALPHAD methodology has been established and summarized from the construction of databases describing thermodynamics, atomic mobility, kinetics, thermo-physical properties (such as viscosity) to the application of computational design of lightweight materials. The examples in this paper have demonstrated the effectiveness and capability of CALPHAD methodology in accelerating the design of advanced lightweight materials by optimizing the compositions and various heat-treatment conditions, modifying the evolution of microstructures during processing, and finally predicting the mechanical properties (e.g., yield strength and hardness) of the lightweight components. Although the examples are given in lightweight alloys for structural applications, the fundamental methodology and modeling principles are applicable to all materials and engineering applications. Thus, the future of the advanced material design will be strongly based on development of CALPHAD methodology such as the construction of reliable databases coupled with CALPHAD-based models for various applications.

36 MATERIALS SCIENCE↗
DOE OSTI2019

A review of computational modeling techniques in study and design of shape memory ceramics

Shape memory ceramics are a unique family of shape memory materials with a wide variety of applications, such as ultra-high energy dissipation and high-temperature actuation. Along with significant progress in the experimental study of zirconia-based shape memory ceramics in recent years, computational simulations have exhibited powerful capabilities in revealing nano/microstructure-dependent deformation and failure mechanisms in these materials. In this work, we review the recent progress in understanding the phase transformation behavior in shape memory ceramics, focusing on computational modeling of zirconia-based ceramics. Electronic structure calculations have provided new data on the phase stability and surface properties of shape memory ceramics. At the nanometer length scale, molecular dynamics simulations have captured fundamental information about martensitic phase transformation and the effects of grain boundaries and defects on mechanical response of bi- and polycrystalline zirconia-based ceramics. At the micrometer length scale, advanced phase-field models have shown the ability to predict morphological evolution of microstructures and the corresponding mechanical responses in good agreement with experimental observations. Despite the recent multiscale computational advancements, further developments are required to establish processing-structure-property-performance relations that will lead to reliable and practical strategies for designing zirconia-based (or other) ceramics with improved and sustained shape memory responses. This article critically reviews current computational modeling techniques and provides an outlook for the study and design of the next generation of shape memory ceramics.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Computational modeling of grain boundary segregation: A review

Nearly all metals, alloys, ceramics, and their associated composites are polycrystalline in nature, with grain boundaries that separate well-defined crystalline regions that influence materials properties. In all but the most pure elemental systems, intentional solutes or impurities are present and can segregate to, or less commonly away from, the grain boundaries, in turn influencing boundary behavior, their stability, and associated materials properties. In some cases, grain-boundary segregation can also trigger “phase-like” structural transitions that dramatically alter the essential nature of the boundary. With the development of advanced electron microscopy techniques, researchers can directly observe grain-boundary structures and segregation with atomic precision. Despite such spatial resolution, the underlying mechanisms governing grain-boundary segregation remain difficult to characterize. As a result, computational modeling techniques such as density functional theory, molecular dynamics, mesoscale phase-field, continuum defect theory, and others are important complementary tools to experimental observations for studying grain-boundary segregation behavior. In conclusion, these computational methods offer the ability to explore the underlying formation mechanisms of grain-boundary segregation, elucidate complex segregation behavior, and provide insights into solutions to effectively controlling microstructure.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Development and performance of INCONEL® alloy 740H® seam-welded piping

INCONEL® alloy 740H® is an age-hardenable nickel-based alloy approved for pressure vessels and piping within ASME Section I, VIII, and B31.1. Currently, the code applies a weld strength reduction factor (WSRF) of 0.7 to the allowable stresses for longitudinal seam welds in the time dependent creep regime. In this work, a full-scale seam weld was successfully produced using typical industrial practices. The component was solution heat-treated and aged after fabrication to improve the performance of the weldment. Tensile, bend, impact, and low-cycle fatigue tests showed the component met all the specification requirements and elevated temperature properties were within base metal expectations with failures predominately in the weld metal. Long-term creep tests, including large samples more representative of the entire weldment, were fabricated and tested to times in excess of 10,000 h at multiple temperatures. Analysis of the creep data supports a WSRF of 0.9 for the solution annealed + aged weldments in contrast to the WSRF of 0.7 currently applied to welded + aged weldments. Metallurgical analysis shows that the solution annealing causes recrystallization of the weld metal and reduces the chemical compositional and microstructural gradients in the weldments resulting in acceptable short-term performance. In long-term creep, evidence for coarsened zones in the weldments due to discontinuous coarsening reactions were identified as the mechanism leading to accelerated creep damage formation in the weld metal and sample failure.

14 SOLAR ENERGY↗