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At least 1,405 records · Page 78

Advanced characterization-informed machine learning framework and quantitative insight to irradiated annular U-10Zr metallic fuels

Abstract U-10Zr Metal fuel is a promising nuclear fuel candidate for next-generation sodium-cooled fast spectrum reactors. Since the Experimental Breeder Reactor-II in the late 1960s, researchers accumulated a considerable amount of experience and knowledge on fuel performance at the engineering scale. However, a mechanistic understanding of fuel microstructure evolution and property degradation during in-reactor irradiation is still missing due to a lack of appropriate tools for rapid fuel microstructure assessment and property prediction based on post irradiation examination. This paper proposed a machine learning enabled workflow, coupled with domain knowledge and large dataset collected from advanced post-irradiation examination microscopies, to provide rapid and quantified assessments of the microstructure in two reactor irradiated prototypical annular metal fuels. Specifically, this paper revealed the distribution of Zr-bearing secondary phases and constitutional redistribution across different radial locations. Additionally, the ratios of seven different microstructures at various locations along the temperature gradient were quantified. Moreover, the distributions of fission gas pores on two types of U-10Zr annular fuels were quantitatively compared.

36 MATERIALS SCIENCE↗

Application of NSUF Capabilities Towards Understanding the Emulation of High Dose Neutron Irradiations with Ion Beams

Development of new materials for current nuclear power plants (NPPs) or materials for new NPPs requires extensive research, development, and deployment programs. Central to these efforts, particularly for core internals, are studies on the microstructural and mechanical changes due to neutron irradiation. These radiation effects studies are typically completed using materials test reactors followed by expensive and time-consuming post-irradiation examinations (PIE). This sluggish approach has severely limited the nuclear materials field to develop new materials or verify materials for new reactor design use. It is also very difficult to achieve the high levels of damage proposed for future reactors. A logical approach to accelerating the field is the application of ion beams to simulate neutron damage, especially for high dose applications. Ion beams have been used for decades to study radiation effects but not to emulate high dose reactor irradiations. In this regard, new (or renewed) methods for ion beam irradiations, new developments in materials characterization, and greater understanding on the governing mechanisms controlling observed radiation effects have led to a need for further studies to refine the technique. A primary challenge is the ability to determine the ion irradiation conditions that produce microstructures and mechanical properties relevant to in-core neutron irradiation conditions. A large, multi-disciplinary, multi-laboratory program deemed the High Fidelity Ion Beam Simulation of High Dose Neutron Irradiation has been formed to assess and overcome the challenges associated with emulating high dose neutron irradiations using ion beams. Central to this program is the use of dual-beam ion irradiations and corresponding neutron irradiations within the BOR-60 fast reactor. These irradiations have produced hundreds of specimens for microstructural and mechanical characterization. A significant issue regarding the samples is the radioactivity of the neutron irradiated specimens as well as the need to characterize both irradiation types using the same equipment to maintain consistency and repeatability. The use of the Nuclear Science User Facilities (NSUF) has been central towards overcoming the mentioned issues and thereby enabling robust PIE in both the ion and neutron irradiated specimens of interest. In particular, the electron microscopes housed within the Low Activation Materials Development and Analysis (LAMDA) facility at Oak Ridge National Laboratory (ORNL) - an NSUF partner facility - has been instrumental in gathering high quality data for analysis. This paper will briefly highlight the PIE efforts using the NSUF capabilities within LAMDA.

36 MATERIALS SCIENCE↗

Automated coupling of NanoIndentation and Quantitative Energy-Dispersive Spectroscopy (NI-QEDS): A comprehensive method to disclose the micro-chemo-mechanical properties of cement pastes

Engineering cement-based composites requires a comprehensive understanding of the microstructure features governing macroscopic properties. This work aims to foster the latest chemo-mechanical technique to disclose the micro-mechanical properties of intimately intermixed phases. Considering a typical Portland cement paste as a study case, we compared the so-far developed nanoindentation analysis methods with a new automatic method coupling Nano-Indentation and Quantitative Energy-Dispersive Spectroscopy (NI-QEDS). Besides evincing advantages and disadvantages of previous methods, the NI-QEDS analyses enabled distinguishing chemical phases having strongly overlapping mechanical properties. Results suggested the presence at the sub-micrometre scale of extra calcium, aluminum and sulfur into (or in the vicinity of) outer C–S–H. The quantitative chemistry allowed identifying the rare occurrence of nanoindentation volumes located on ''pure'' phases (e.g., inner C–S–H). Finally, NI-QEDS provided new knowledge on cement pastes' micro-chemo-visco-mechanical properties and showed to be a powerful tool for investigating even more heterogeneous systems.

36 MATERIALS SCIENCE↗

Hybrid Al Casting + AM Components for Automotive Applications

Although casting Aluminum (Al) alloys is widely used for automotive application, the conventional casting process is showing limitations for modern vehicle production. A hybrid manufacturing method that is capable of fabricating automotive structures with tailored functionality and tuned attributes at a high production rate is proposed in this project, utilizing the merits of conventional casting methods and additive manufacturing (AM) methods. Ford is interested in supplementing conventional casting processes (e.g., shape casting, high pressure die casting) with local modifications to geometry and microstructure using additive manufacturing techniques. Two additive manufacturing methods, wire-arc and laser hot-wire directed energy deposition AM process, were evaluated by deposition of 4043 filler wire onto high-pressure die cast and permanent mold cast Al-Si alloys. The feasibility of this hybrid manufacturing method was determined through trial deposition and evaluation of defects, microstructure, and mechanical properties. Laser hot-wire deposition was found to be beneficial for this application with low porosity, a refined microstructure, and mechanical properties similar to those reported in the literature for 4043. The mechanical properties of the interface between the A356 casting and deposited 4043 were found to be controlled by the weaker deposit material.

36 MATERIALS SCIENCE↗

Pulsed-Laser Irradiation Space Weathering Of A Carbonaceous Chondrite

Grains on the surfaces of airless bodies experience irradiation from solar energetic particles and melting, vaporization and recondensation processes associated with micrometeorite impacts. Collectively, these processes are known as space weathering and they affect the spectral properties, composition, and microstructure of material on the surfaces of airless bodies, e.g. Recent efforts have focused on space weathering of carbonaceous materials which will be critical for interpreting results from the OSIRIS-REx and Hayabusa2 missions targeting primitive, organic-rich asteroids. In addition to returned sample analyses, space weathering processes are quantified through laboratory experiments. For example, the short-duration thermal pulse from hypervelocity micrometeorite impacts have been simulated using pulsed-laser irradiation of target material e.g. Recent work however, has shown that pulsed-laser irradiation has variable effects on the spectral properties and microstructure of carbonaceous chondrite samples. Here we investigate the spectral characteristics of pulsed-laser irradiated CM2 carbonaceous chondrite, Murchison, including the vaporized component. We also report the chemical and structural characteristics of specific mineral phases within the meteorite as a result of pulsed-laser irradiation.

Thompson, M. S.↗

Assessment of Low Cycle Fatigue Behavior of Powder Metallurgy Alloy U720

The fatigue lives of modem powder metallurgy disk alloys are influenced by variabilities in alloy microstructure and mechanical properties. These properties can vary as functions of variables the different steps of materials/component processing: powder atomization, consolidation, extrusion, forging, heat treating, and machining. It is important to understand the relationship between the statistical variations in life and these variables, as well as the change in life distribution due to changes in fatigue loading conditions. The objective of this study was to investigate these relationships in a nickel-base disk superalloy, U720, produced using powder metallurgy processing. Multiple strain-controlled fatigue tests were performed at 538 C (1000 F) at limited sets of test conditions. Analyses were performed to: (1) assess variations of microstructure, mechanical properties, and LCF failure initiation sites as functions of disk processing and loading conditions; and (2) compare mean and minimum fatigue life predictions using different approaches for modeling the data from assorted test conditions. Significant variations in life were observed as functions of the disk processing variables evaluated. However, the lives of all specimens could still be combined and modeled together. The failure initiation sites for tests performed at a strain ratio R(sub epsilon) = epsilon(sub min)/epsilon(sub max) of 0 were different from those in tests at a strain ratio of -1. An approach could still be applied to account for the differences in mean and maximum stresses and strains. This allowed the data in tests of various conditions to be combined for more robust statistical estimates of mean and minimum lives.

Gabb, Tomothy P.↗

Microstructure and partitioning behavior characteristics in low carbon steels treated by hot-rolling direct quenching and dynamical partitioning processes

In this work, a new process and composition design are proposed for “quenching and partitioning” or Q&P treatment. Three low carbon steels were treated by hot-rolling direct quenching and dynamical partitioning processes (DQ&P). The effects of proeutectoid ferrite and carbon concentration on microstructure evolution and mechanical properties were investigated. The present work obtained DQ&P prototype steels with good mechanical properties and established a new notion on compositions for Q&P processing. Microstructures were characterized by means of electro probe microanalyzer (EPMA), scanning electron microscopy (SEM), electron backscatter diffraction (EBSD), transmission electron microscopy (TEM) and X-ray diffraction (XRD), especially the morphology and size of retained austenite. Mechanical properties were measured by uniaxial tensile tests. The results indicated that introducing proeutectoid ferrite can increase the volume fraction of retained austenite and thus improve mechanical properties. TEM observation showed that retained austenite included the film-like inter-lath austenite and blocky austenite located in martensite/ferrite interfaces or surrounded by ferrites. It was interesting that when the carbon concentration is as low as ~ 0.078%, the film-like inter-lath untransformed austenite cannot be stabilized to room temperature and almost all of them transformed into twin martensite. The blocky retained austenite strengthened the interfaces and transformed into twin martensite during the tensile deformation process. The PSEs of specimens all exceeded 20 GPa.%. - Highlights: •This study focused on a new process: Q&P process applying dynamical partitioning. •Ferrite can increase the volume fraction of retained austenite. •The film-like austenite and the blocky austenite were observed. •The low carbon steels treated by new process reached PSEs higher than 20 GPa.%.

36 MATERIALS SCIENCE↗

Characterization of the fatigue threshold behavior of UHMWPE

Ultra-high-molecular-weight-polyethylene (UHMWPE) has been the material of choice for bearings in total joint replacements (TJRs) for decades as a result of its excellent wear resistance, chemical inertness, energetic toughness, low friction, and biocompatibility. Utilization of this polymer in orthopedic devices requires oxidation, wear, and fatigue resistance. Balancing these important properties by tailoring processing techniques and modulating microstructural features has been an ongoing endeavor in the field. Research into the clinical applications of UHMWPE has primarily focused on the challenges of wear and oxidation while studies into the realm of fatigue have been more limited. Literature gaps exist in fully understanding the fatigue crack initiation near notches or propagation of small existing flaws in UHMWPE used in TJRs. In particular, the characterization of the fatigue thresholds and near-threshold fatigue behavior of orthopedic grade UHMWPE has yet to be thoroughly explored. In this work, we characterized the fatigue crack arrest threshold of clinically-relevant UHMWPE formulations. Correlations between the fatigue thresholds and bulk mechanical properties as well as microstructural properties were examined across these medical resins. The important role played by crosslinking in influencing the fatigue performance of UHMWPE is highlighted in this study. In addition, it is established that J-integral fracture toughness is the best predictor of fatigue thresholds and could possibly be used as a stand-in metric for fatigue performance if thresholds cannot be directly ascertained. Finally, this study corroborates that the true constitutive parameters best describe the mechanical behavior of UHMWPE.

Cross-linking↗

Influence of non-magnetic Cu on enhancing the low temperature magnetic properties and Curie temperature of FeCoNiCrCu(x) high entropy alloys

The microstructure and magnetic properties of three face-centered cubic (FCC) FeCoNiCrCu(x) high entropy alloys (HEAs) (x=0, 0.5, 1) are investigated. Interestingly, addition of the nonmagnetic element Cu to FeCoNiCr HEA is found to enhance exchange interactions and low temperature saturation magnetization. The paramagnetic to ferromagnetic Curie transition temperature increases from 85 K for FeCoNiCr to 118 K for FeCoNiCrCu. This is counterintuitive since Cu is nonmagnetic; however, atom probe tomography revealed Cu rich clusters containing 5 at% Ni and 1 at% each of Fe, Co, Cr, within FCC matrix, these clusters altered the matrix composition and consequently its magnetic properties.

Chaudhary, Varun↗

Microstructural evolution, defect mitigation, and precipitation behavior in AA6061 via laser powder bed fusion with high-temperature substrate heating

Defects, particularly solidification cracking, remain persistent challenges in the laser powder bed fusion (LPBF) processing of AA6061 aluminum alloy. This study systematically investigates defect mitigation, microstructural evolution, and mechanical properties associated with high-temperature substrate preheating at 500 °C. Comprehensive microstructural analyses, including characterization of defects, grain structures, and precipitation behavior, were performed on samples in both as-built and T6 heat-treated states. Elevated preheating substantially reduced solidification cracking across a wide processing window, while demonstrating decreased crack sensitivity to laser parameters. Columnar cracks along the build direction were observed despite substrate preheating. Lack-of-fusion and keyhole porosity were effectively eliminated, though gas-induced microporosity persisted at higher powers. In-depth characterization of two distinct laser power and speed conditions confirmed the formation of micron-sized, non-coherent Mg 2 Si precipitates under heated substrate conditions, alongside α-AlFeCrMnSi intermetallic phases indicative of in-situ thermal effects during fabrication. Subsequent T6 heat treatment revealed the formation of fine, coherent needle-shaped β″ strengthening precipitates. Despite substantial differences in processing parameters, comparable mechanical properties were measured in the as-built samples (∼52 MPa yield strength, ∼130 MPa tensile strength), primarily due to reduced strain hardening effects and consistent precipitation characteristics. Meanwhile, the T6 heat treatment led to significant improvement in properties, enhancing yield strength by over 400%, aligning closely with the performance of conventional wrought AA6061-T6. These findings underscore that high-temperature substrate preheating offers an effective means to suppress cracks, control precipitation, and enhance mechanical performance in LPBF-processed AA6061.

36 MATERIALS SCIENCE↗

ExaAM: Metal additive manufacturing simulation at the fidelity of the microstructure

Additive manufacturing (AM), or 3D printing, of metals is transforming the fabrication of components, in part by dramatically expanding the design space, allowing optimization of shape and topology. However, although the physical processes involved in AM are similar to those of welding, a field with decades of experimental, modeling, simulation, and characterization experience, qualification of AM parts remains a challenge. The availability of exascale computational systems, particularly when combined with data-driven approaches such as machine learning, enables topology and shape optimization as well as accelerated qualification by providing process-aware, locally accurate microstructure and mechanical property models. We describe the physics components comprising the Exascale Additive Manufacturing simulation environment and report progress using highly resolved melt pool simulations to inform part-scale finite element thermomechanics simulations, drive microstructure evolution, and determine constitutive mechanical property relationships based on those microstructures using polycrystal plasticity. We report on implementation of these components for exascale computing architectures, as well as the multi-stage simulation workflow that provides a unique high-fidelity model of process–structure–property relationships for AM parts. In addition, we discuss verification and validation through collaboration with efforts such as AM-Bench, a set of benchmark test problems under development by a team led by the National Institute of Standards and Technology.

3D printing↗

Cetyltrimethylammonium Bromide (CTAB) Surfactant-Assisted Synthesis of BiFeO{sub 3} Nanoparticles by Sol-Gel Auto-Combustion Method

In this research, BiFeO{sub 3} nanoparticles were synthesized by sol-gel auto-combustion method with and without the addition of cetyltrimethylammonium bromide (CTAB) surfactant. The effect of different amounts of CTAB addition (0, 1.5, 3, and 6 wt.%) on phase constituents, microstructure, and magnetic properties of the synthesized samples were evaluated using X-ray diffraction (XRD), field emission scanning electron microscope (FESEM), and vibration sample magnetometer (VSM). Also, BiFeO{sub 3} nanoparticles were used for the degradation of methylene blue (MB) as a typical dye pollutant under UV irradiation. XRD results showed the formation of BiFeO{sub 3} mainly with some minute impurity phases such as Bi{sub 2}O{sub 3} and γ-Fe{sub 2}O{sub 3}. Proper amounts of CTAB addition (1.5 wt.%) considerably eliminates Bi{sub 2}O{sub 3} and γ-Fe{sub 2}O{sub 3} residuals in the combustion product. FESEM micrographs show particle size reduction and also more uniform particle size distribution when using 0.75 wt.% of CTAB addition. In the presence of the BiFeO{sub 3}, the UV irradiation for 120 min resulted in 26% degradation of MB, in a sample with 0.75 wt.% CTAB. The synthesized nanoparticles of BiFeO{sub 3} in the sample with 0.75 wt.% CTAB after calcination at 650 {sup ∘}C showed a weak ferromagnetism behavior with saturation magnetization of 0.54 emu/g. {sub i}H{sub C} values of the samples are in the range of 200 to 238 Oe, depending on the crystallite size and phase constituents of the samples.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

Heat-treated glassy carbon under pressure exhibiting superior hardness, strength and elasticity

Glassy carbon (GC) is a type of non-graphitizing disordered carbon material at ambient pressure and high temperatures, which has been widely used due to its excellent mechanical properties. Here we report the changes in the microstructure and mechanical properties of GC treated at high pressures (up to 5 GPa) and high temperatures. The formation of intermediate sp 2 –sp 3 phases is identified at moderate treatment temperatures before the complete graphitization of GC, by analyzing synchrotron X-ray diffraction, Raman spectra, and transmission electron microscopy images. The intermediate metastable carbon materials exhibit superior mechanical properties with hardness reaching up to 10 GPa and compressive strength reaching as high as 2.5 GPa, nearly doubling those of raw GC, and improving elasticity and thermal stability. The synthesis pressure used in this study can be achieved in the industry on a commercial scale, enabling the scalable synthesis of this type of strong, hard, and elastic carbon materials.

36 MATERIALS SCIENCE↗

Effect of docetaxel on mechanical properties of ovarian cancer cells

Docetaxel could inhibit the proliferation of tumor cells by targeting microtubules. The extension of cellular microtubules plays an important role in the invasion and metastasis of tumor cells. This paper aims to study the distribution and mechanical properties of cytoskeletal proteins with low concentration of docetaxel. MTT assay was used to detect the minimum drug activity concentration of docetaxel on SKOV-3 cells, fluorescence staining was used to analyze the distribution of cytoskeleton proteins, scanning electron microscopy(SEM) was used to observe the morphology of single cells, and atomic force microscopy(AFM) was used to determine the microstructure and mechanical properties of cells. The results showed that the IC{sub 10} of docetaxel was 1 ng/ml. Docetaxel can effectively inhibit the formation of cell pseudopodia, hinder the indirectness between cells, reduce the cell extension area, and make the cells malformed. In addition, when AFM analyzes the effects of drugs on cell microstructure and mechanical properties, the average cell surface roughness and cell height are positively correlated with the concentration of docetaxel. Especially when the concentration was 100 ng/ml, the adhesion decreased by 37.04% and Young's modulus increased by 1.57 times compared with the control group. This may be because docetaxel leads to microtubule remodeling and membrane protein aggregation, which affects cell microstructure and increases cell strength, leading to significant changes in the mechanical properties of ovarian cells. This is of great significance to the study of the formation mechanism of tumor cell invasion and migration activities mediated by actin.

60 APPLIED LIFE SCIENCES↗

Fatigue Resistance of the Grain Size Transition Zone in a Dual Microstructure Superalloy Disk

Mechanical property requirements vary with location in nickel-based superalloy disks. To maximize the associated mechanical properties, heat treatment methods have been developed for producing tailored microstructures. In this study, a specialized heat treatment method was applied to produce varying grain microstructures from the bore to the rim portions of a powder metallurgy processed nickel-based superalloy disk. The bore of the contoured disk consisted of fine grains to maximize strength and fatigue resistance at lower temperatures. The rim microstructure of the disk consisted of coarse grains for maximum resistance to creep and dwell crack growth at high temperatures up to 704 C. However, the fatigue resistance of the grain size transition zone was unclear, and needed to be evaluated. This zone was located as a band in the disk web between the bore and rim. Specimens were extracted parallel and transverse to the transition zone, and multiple fatigue tests were performed at 427 and 704 C. Mean fatigue lives were lower at 427 C than for 704 C. Specimen failures often initiated at relatively large grains, which failed on crystallographic facets. Grain size distributions were characterized in the specimens, and related to the grains initiating failures as well as location within the transition zone. Fatigue life decreased with increasing maximum grain size. Correspondingly, mean fatigue resistance of the transition zone was slightly higher than that of the rim, but lower than that of the bore. The scatter in limited tests of replicates was comparable for all transition zone locations examined.

Gabb, T. P.↗

Processing and properties of SiC whisker- and particulate-reinforced reaction bonded Si3N4

The microstructure and mechanical properties of reaction bonded Si3N4 (RBSN) reinforced with SiC whiskers of particles were investigated using RBSN composites made from colloidally pressed octanol dispersions of high-purity Si powders mixed with either SiC whiskers or alpha-SiC particles. Results of investigations, revealing high conversions of Si to Si3N4, specific surface areas, and constant relative densities and strengths, showed that the uniform microstructure and small flaw size of the matrix were maintained in the composites and that no degradation of the reinforcements was taking place. Neither the monolithic nor the composite materials exhibited R-curve behavior. A modest increase in fracture toughness was observed only in the RBSN containing 33 vol pct SiC(p).

Lightfoot, A.↗

Phase-control synthesis and catalytic property of magnetic Ni@NixPy core-shell microstructures

Highlights: • Ni@Ni{sub x}P{sub y} core-shell microstructures are synthesized by a low-temperature phosphidation route. • The initial Ni/NaH{sub 2}PO{sub 2} molar ratio can strongly affect the phase of the final product. • Ni@Ni{sub x}P{sub y} microstructures present good catalytic activity for the reduction of 4-nitrophenol. • The catalytic property of Ni@Ni{sub x}P{sub y} microstructures presents markedly phase-dependent features. - Abstract: Magnetic Ni@Ni{sub x}P{sub y} core-shell microstructures were successfully synthesized by a simple low-temperature phosphidation route, employing Ni nanospheres as the initial nickel source, NaH{sub 2}PO{sub 2}·H{sub 2}O as the phosphorus ion source. The phosphidation reaction was carried out in N{sub 2} atmosphere at 300 °C for 2 h. Experiments showed that the initial Ni/NaH{sub 2}PO{sub 2} molar ratio could strongly affect the phase of the final product. When the Ni/NaH{sub 2}PO{sub 2} molar ratio of 1:2.77 was used, hexagonal Ni{sub 2}P phase was obtained; while the Ni/NaH{sub 2}PO{sub 2} molar ratio was 1:5.54, hexagonal Ni{sub 5}P{sub 4} phase was produced. It was found that the magnetic properties of the products gradually decreased with the conversion from Ni nanospheres, to Ni@Ni{sub 2}P and to Ni@Ni{sub 5}P{sub 4}. Moreover, initial Ni nanospheres, Ni@Ni{sub 2}P and Ni@Ni{sub 5}P{sub 4} core-shell microstructures presented outstanding catalytic activities for the reduction of 4-nitrophenol (4-NP) to 4-aminophenol (4-AP) in excess NaBH{sub 4} solution. Ni@Ni{sub 5}P{sub 4} core-shell microstructures owned the best catalytic activity.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

A laser ultrasonics-based approach for rapid screening of high entropy alloys

This project demonstrates a laser ultrasonics-based characterization methodology for rapid metallic materials design and discovery via in situ determination of phases, microstructures and elastic properties with respect to temperature. Ultrasonic waves are strongly affected by material microstructure, and therefore serve as a facile means to probe elastic properties, phase content and their size distributions and volume fractions. In this study, a laser ultrasonic technique is used to systematically study the evolution of properties in a set of interrelated simple binary alloys and high entropy alloys (HEA). Phase transformations and microstructural changes inferred from the ultrasonic signals will be correlated with electron microscopy data and predictions using calculations of phase diagrams (CALPHAD). The non-contact and non-destructive ultrasonic testing approach developed in this study could overcome several limitations associated with current material characterization methods for materials discovery. It is expected that laser ultrasonics-based methodology developed in this work will be utilized to evaluate novel graded composition HEAs currently being developed at the Idaho National Laboratory (INL) using advanced manufacturing methods based on direct energy deposition and spark plasma sintering processes, and contribute to accelerate the discovery of HEAs.

36 MATERIALS SCIENCE↗