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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 1,405 records · Page 78
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Enhancement of Thermal Conductivity and Mechanical Properties of Cu-Reduced Graphene Oxide Composites by Interface Modification

Copper matrix composites reinforced with reduced graphene oxide (rGO) were fabricated via charge adsorption process, thermal reduction, and hot-press sintering process. We investigated the effect of rGO on the thermal conductivity, electrical conductivity, mechanical properties, and microstructure of the composites. By controlling the reaction process, copper on the rGO surface was oxidized to form Cu{sub 2}O. The presence of Cu{sub 2}O at the interface enhanced interfacial bonding strength and reduced the interfacial thermal resistance, thus improving the thermal conductivity and mechanical properties. This enhancement occurred at low rGO contents. By contrast, excessive amounts led to rGO agglomeration and a degradation of the performance. At the optimum rGO content of 0.6 wt.%, the composites had a 10% increase in thermal conductivity and a 46% increase in yield strength (σ{sub 0.2}), while maintaining high electrical conductivity.

36 MATERIALS SCIENCE↗
DOE OSTI2019

A New Approach for Consolidation of Pure Magnesium Powder Using an Integrated Severe Plastic Deformation Route

In this paper, a new approach using a novel severe plastic deformation route is presented for consolidation and processing of a high-density and ultrafine-grained pure magnesium. Pure magnesium particles were successfully consolidated at 400 °C into a sufficiently dense bulk material using a new combined method including cyclic extrusion compression, equal channel angular pressing (ECAP) and conventional extrusion. The grain refinement, consolidation behavior and mechanical properties were deeply investigated. Results showed that the as-consolidated material had a fine grain structure with excellent tensile strength and ductility compared to as-cast and as-ECAPed specimens. Vickers microhardness increased from 38.75 to 52.58 during the process. Porosity also reduced considerably from 12.55 to 1.2% during the process which led to a dense bulk material. Results indicate that the introduced method is a promising and effective process for producing strong bulk materials from metal powders.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Microstructure and Mechanical Properties of B{sub 4}C-Blended M3:2 High-Speed Steel Powders Consolidated by Sintering and Heat Treatment

Water-atomized powders of M3:2 high-speed steel (HSS) were blended with B{sub 4}C and consolidated by cold press sintering. With the addition of B{sub 4}C (~ 0.2 vol.%), satisfactory mechanical properties were achieved for HSS by sintering at a temperature as low as 1190 °C [e.g., 53.2 ± 0.2 in the Rockwell hardness (HRC) and 3074 ± 56 MPa in bending strength]. High relative density (98.5%) and good strength were attributed to the mechanism described as follows: First, the atoms of boron and carbon escaped after the reaction between B{sub 4}C and iron matrix. Then, the sintered HSS was strengthened by boron atoms while they were distributed in M{sub 6}C or MC carbides and iron matrix. Second, a plenty of M{sub 6}C carbides were formed due to the release of carbon atoms. As a result, the value of solidus temperature was reduced. In addition, mechanical properties were greatly improved by heat treatment (quenching and tempering) (e.g., 61.2 ± 0.3 in HRC, 4356 ± 64 MPa in bending strength, and 42.3 ± 0.5 MPa m{sup 1/2} in fracture toughness, respectively).

36 MATERIALS SCIENCE↗
DOE OSTI2017

Current and Future Uses of Aluminum in the Automotive Industry

Aluminum use is growing in automotive closures and body in white applications to improve vehicle performance and fuel economy. The auto industry is looking for higher strength aluminum materials needed for strength driven safety critical parts. Through cooperation with industrial partners and support from the Department of Energy (DOE), multiple experimental 7xxx alloys were developed for automotive applications. The objective is to enable complex shapes to be formed at temperatures below 225° C. A demonstration part has been developed that is representative of the forming challenges within a current hot stamped door ring component. This part tooling has been built and installed into a press line which includes blank heating and robotic transfer. Forming trials of these alloys are currently underway and the formability, strength and corrosion performance of these materials are being evaluated.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Cryogenic Stress-Driven Grain Growth Observed via Microcompression with in situ Electron Backscatter Diffraction

The deformation of materials at cryogenic temperature is of interest for space, arctic, and fundamental science applications. In this work, a custom-built cooling system attached to a commercial picoindenter was used for in situ cryogenic microcompression testing of equal-channel angular-pressed copper with real-time electron backscatter diffraction. Stress-driven grain growth at cryogenic temperatures was observed during a series of elastic and plastic deformations. Finally, these results provide direct evidence for the previously predicted phenomenon, whereas previous ex situ examinations demonstrated coarsening after cryogenic loading when samples were not maintained at cryogenic temperatures between deformation and characterization.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Creep Deformation and Damage Mechanisms in an Advanced High-Temperature Additively Manufactured Nickel-Base Superalloy

Abstract This research investigates the processing–structure–properties–performance relationship in a novel nickel-base superalloy, ABD ® -900AM, designed for extreme environments. Specifically tailored for additive manufacturing (AM), ABD ® -900AM maintains mechanical integrity at high temperatures and is comparable to other nickel-based superalloys with a 30–40% gamma-prime volume fraction. A comprehensive study was conducted using laser-beam powder bed fusion and electron-beam powder bed fusion methods. Factors such as heat treatment, porosity, build orientation, and hot isostatic pressing were evaluated to understand their effects on microstructure and mechanical performance. Microstructural characterization revealed significant differences in grain size and orientation across build processes and heat treatments. High-temperature mechanical testing indicated that grain size, heat treatment, and orientation significantly influence creep behavior. A super-solvus heat treatment led to recrystallization and grain growth, significantly improving creep properties compared to a near-solvus heat treatment. Various creep mechanisms were identified across different conditions, and creep rupture models were developed for each build process. Post-test microstructural analysis showed grain boundary damage, with differences in creep cavitation morphology under varying stress conditions. It was shown that MC carbides grow at the expense of gamma-prime near grain boundaries, leading to precipitate-free zones in specimens tested at higher temperatures. This study fills a significant gap in fundamental research by offering a deeper insight into the high-temperature mechanical behavior of additively manufactured nickel-base superalloys. It also explores critical research questions regarding the role of carbides and the significance of heat treatment. The insights gained enhance confidence in the industry adoption of ABD ® -900AM and similar alloys for high-temperature applications, bridging the knowledge gap and supporting the development of reliable AM processes for extreme environments.

Bridges, Alex (ORCID:000000030338759X)↗
DOE OSTI2019

Synthesis and Characterization of Natural Nano-hydroxyapatite Derived from Turkey Femur-Bone Waste

Hydroxyapatite (HAp) is a bioactive and vital material which has found many applications in the biomedical and clinical fields. This bio-ceramic powder can be synthesized via different bio-waste materials. In this study, the production of natural nanohydroxyapatite was produced through calcination of untreated turkey femur-bone waste powder at 850 °C followed by ball milling the powder. The obtained powder was characterized using X-ray diffraction (XRD) and Fourier transform infrared spectroscopy (FTIR) analysis. The morphology, size, and elemental composition of obtained turkey hydroxyapatite (THA) particles were investigated by scanning electron microcopy (SEM), transmission electron microcopy (TEM), and energy dispersive spectroscopy (EDS) analysis, in which the average particle size of ball milled THA was found to be about 85 nm with a Ca/P ratio of 1.63. The powder was then cold pressed and later sintered at 850, 950, 1050, and 1150 °C to evaluate its mechanical properties in terms of compressive strength and hardness. The results revealed that the strength and hardness of the samples increased by increasing the sintering temperature up to 1150 °C. Finally, the maximum values of hardness and compressive strength of the sintered THA were obtained at 1150 °C (37.44 MPa and 3.2 GPa, respectively).

60 APPLIED LIFE SCIENCES↗
DOE OSTI2019

Al–CNT–Ni composite with significantly increased strength and hardness

Here, aluminium–carbon nanotube–nickel (Al–CNT–Ni) composite was prepared by powder metallurgy from pure Al powder and Ni-encapsulated CNT. Previously, carbon nanotubes were coated with nickel following ultraviolet-assisted electroless deposition method. Tensile strength and hardness of the composites were found to increase in proportion to the CNTs addition. For an addition of 7 wt.% Ni-coated CNTs containing 2.5 wt.% nanotubes of 8–15 nm diameter (Ni to CNT ratio was 1–0.357), resultant tensile and yield strength were increased by 129.26% and 157.48% respectively compared to pure aluminium. Hardness was also increased by 171.39%. These results were obtained while conventional sintering was followed by further consolidation by Hot Isostatic Pressing (HIP). Enhanced mechanical properties are attributed to the well dispersion of CNTs in aluminium matrix and strong interfacial bonding between CNT and aluminium. Lastly, well dispersion of CNTs and strong interfacial bonding was resulted from the uniform Ni-encapsulation as verified by red shift in Raman Spectroscopy.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Scheduling and Performance of Asynchronous Tasks in Fortran 2018 with FEATS

Most parallel scientific programs contain compiler directives (pragmas) such as those from OpenMP (Hermanns in Parallel programming in Fortran 95 using openMP, 2002. School of Aeronautical Engineering, Universidad Politécnica de Madrid, España, 2011), explicit calls to runtime library procedures such as those implementing the Message Passing Interface (MPI) (in A message-passing interface standard version 4.0, 2021. https://www.mpi-forum.org/docs/mpi-4.0/mpi40-report.pdf), or compiler-specific language extensions such as those provided by CUDA (Ruetsch and Fatica in CUDA Fortran for scientists and engineers: best practices for efficient CUDA Fortran programming, Elsevier, 2013). By contrast, the recent Fortran standards empower developers to express parallel algorithms without directly referencing lower-level parallel programming models (Numrich in Parallel programming with co-arrays, CRC Press, 2018, and Curcic in Modern Fortran: building efficient parallel applications, Manning Publications, 2020). Fortran’s parallel features place the language within the Partitioned Global Address Space (PGAS) class of programming models. When writing programs that exploit data parallelism, application developers often find it straightforward to develop custom parallel algorithms. Problems involving complex, heterogeneous, staged calculations, however, pose much greater challenges. Such applications require careful coordination of tasks in a manner that respects dependencies prescribed by a directed acyclic graph. When rolling one’s own solution proves difficult, extending a customizable framework becomes attractive. Further, the paper presents the design, implementation, and use of the Framework for Extensible Asynchronous Task Scheduling (FEATS), which we believe to be the first task scheduling tool written in modern Fortran. We describe the benefits and compromises associated with choosing Fortran as the implementation language, and we propose ways in which future Fortran standards can best support the use case in this paper.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2012

Effect of ball-milling surfactants on the interface chemistry in hot-compacted SmCo5 magnets

Anisotropic SmCo5 nanoflakes prepared by high-energy ball-milling with surfactants have great potential in applications for high-performance nanocomposite magnets. For such "nanocomposite" applications, the surface structure and chemistry of nanoflakes are crucial for achieving high coercivity. In this study, hot-pressed samples from anisotropic SmCo5 nanoflakes, ball-milled with different surfactants, oleic acid (OA) and oleylamine (OY), were investigated. Interface layers between the SmCo5 nanoflakes were found to consist of samarium oxides and a soft magnetic Co phase. These surface layers contribute to the degradation of hard magnetic performance, which is confirmed by scanning transmission electron microscopy-energy dispersive X-ray spectroscopy analysis of the cross-section of a single flake ball-milled with OA. Samples milled with OY show a much thinner interface layer in compacted samples, which means that the surface degradation during ball-milling with OY is much less than that with OA. The results show clearly that the choice of proper surfactant and the control of processing parameters are the key factors for improving the surface condition of the nanoflakes and the resulting hard magnetic properties. (C) 2012 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.

Li, WF↗
DOE OSTI2019

First-principles study, fabrication and characterization of (Zr 0.25 Nb 0.25 Ti 0.25 V 0.25 )C high-entropy ceramics

The formation possibility of a new (Zr 0.25 Nb 0.25 Ti 0.25 V 0.25 )C high-entropy ceramics (ZHC-1) was first analyzed by the first-principles calculations and thermodynamical analysis and then it was successfully fabricated by hot pressing sintering technique. The first-principles calculation results showed that the mixing enthalpy of ZHC-1 was 5.526 kJ/mol and the mixing entropy of ZHC-1 was in the range of 0.693R–1.040R. The thermodynamical analysis results showed that ZHC-1 was thermodynamically stable above 959 K owing to its negative mixing Gibbs free energy. The experimental results showed that the as-prepared ZHC-1 (95.1% relative density) possessed a single rock-salt crystal structure, some interesting nano-plate-like structures, and high compositional uniformity from nanoscale to microscale. By taking advantage of these unique features, compared with the initial metal carbides (ZrC, NbC, TiC and VC), it showed a relatively low thermal conductivity of 15.3 ± 0.3 W/(m·K) at room temperature, which was due to the presence of solid solution effects, nanoplates and porosity. Meanwhile, it exhibited the relatively high nanohardness of 30.3 ± 0.7 GPa and elastic modulus of 460.4 ± 19.2 GPa and the higher fracture toughness of 4.7 ± 0.5 MPam 1/2 , which were attributed to the solid solution strengthening mechanism and nanoplate pullout and microcrack deflection toughening mechanism.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Model for ratchet growth in PBX 9502

Polycrystalline solids composed of crystals with anisotropic thermal expansion coefficients exhibit ratchet growth (RG), a phenomenon characterized by a cumulative and irreversible volume expansion that develops upon exposing the material to cyclic excursions in temperature. We developed a statistical model for RG. The model attributes RG to the formation of intergranular cracks caused by tessellated internal stresses that develop during the thermal excursions. It is postulated that different sets of internal cracks form upon heating and cooling the polycrystalline solid. The model reproduces RG measurements in pressed TATB and PBX 9502 energetic materials and suggests an explanation for why the amplitude of RG generated by a heating excursion is larger than that generated by a subsequent cooling excursion of the same amplitude.

36 MATERIALS SCIENCE↗
DOE OSTI2020

< c+a > dislocations in {101 - 2} twins in Mg: A kinematic and energetic requirement

Consideration of published TEM and molecular dynamics studies of interactions between matrix dislocations and {101¯2} twin boundaries (TB) in hexagonal close packed metals inspires a hypothesis regarding the formation of dislocations with < c+a > Burgers vectors inside the twins. It was previously reported that when basal < a > dislocations from the matrix are swept by an advancing TB, they are converted into partial dislocations bounding basal I 1 stacking faults (SFs) within the twin. In the present work, we show that this dislocation configuration near TB renders it energetically favorable for a pair of partial dislocations to constrict into a dislocation within the twin. New in situ TEM observations confirm this hypothesis by revealing long < c+a > dislocation dipoles terminated by the TB at one end and by I1 SFs within the twin at the other end. Finally, the resulting near-screw < c+a > dislocation dipoles are observed to be glissile, enabling self-annihilation in some circumstances. Thus, rather than requiring a high energy dislocation pile-up to press two < a > dislocations through a TB into a single < c+a > dislocation, it is demonstrated that < c+a > dislocations naturally form, within {101¯2} twins in Mg, as TB migrates into a matrix, which inevitably contains dislocations with < a > Burgers vectors. Furthermore, these observations help to explain how the twins themselves may subsequently deform and why they may be particularly vulnerable to plastic, shear localization.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Bulk nanocrystalline Al alloys with hierarchical reinforcement structures via grain boundary segregation and complexion formation

Grain size engineering, particularly reducing grain size into the nanocrystalline regime, offers a promising pathway to further improve the strength-to-weight ratio of Al alloys. Unfortunately, the fabrication of nanocrystalline metals often requires non-equilibrium processing routes, which typically limit the specimen size and require large energy budgets. In this study, multiple dopant elements in ternary Al alloys are deliberately selected to enable segregation to the grain boundary region and promote the formation of amorphous complexions. Three different fully dense bulk nanocrystalline Al alloys (Al-Mg-Y, Al-Fe-Y, and Al-Ni-Y) with small grain sizes were successfully fabricated using a simple powder metallurgy approach, with full densification connected directly to the onset of amorphous complexion formation. All the compositions demonstrate densities above 99% with grain sizes <60 nm following consolidation via hot pressing at 585 °C. The very fine grain structure results in excellent mechanical properties, as evidenced by nanoindentation hardness values in the range of 2.2-2.8 GPa. Detailed microstructural characterization verifies the segregation of all dopant species to grain boundaries as well as the formation of amorphous complexions, which suggests their influential role in aiding effective consolidation and endowing thermal stability in the alloys. Moreover, nanorods with a core-shell structure are also observed at the grain boundaries, which likely contribute to the stabilization of the grain structure while also strengthening the materials. Lastly, intermetallic particles with sizes of hundreds of nanometers form in all systems. As a whole, the results presented here demonstrate a general alloy design strategy of segregation and boundary evolution pathway that enables the fabrication of multiple nanocrystalline Al alloys with hierarchical microstructures and improved performance.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Solidification modes during additive manufacturing of steel revealed by high-speed X-ray diffraction

Solidification during fusion-based additive manufacturing (AM) is characterized by high solidification velocities and large thermal gradients, two factors that control the solidification mode of metals and alloys. Using two synchrotron-based, in situ setups, we perform high-speed X-ray diffraction measurements to investigate the impact of the solidification velocities and thermal gradients on the solidification mode of a hot-work tool steel over a wide range of thermal conditions of relevance to AM of metals. The solidification mode of primary δ-ferrite is observed at a cooling rate of 2.12x10 4 K/s, and at a higher cooling rate of 1.5x10 6 K/s, δ-ferrite is sup-pressed, and primary austenite is observed. The experimental thermal conditions are evaluated and linked to a Kurz-Giovanola-Trivedi (KGT) based solidification model. The modelling results show that the predictions from the multicomponent KGT model agree with the experimental observations. This work highlights the role of in situ XRD measurements for a fundamental understanding of the microstructure evolution during AM and for vali-dation of computational thermodynamics and kinetics models, facilitating parameter and alloy development for AM processes.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Dislocation channel broadening–A new mechanism to improve irradiation-assisted stress corrosion cracking resistance of additively manufactured 316 L stainless steel

Additively manufactured (AM) 316 L stainless steel (SS) after hot isostatic pressing (HIP) was found to exhibit superior resistance to irradiation-assisted stress corrosion cracking (IASCC) in high-temperature water, as compared to wrought 316 L SS. The well-accepted IASCC factors of radiation-induced segregation (RIS) and radiation hardening are not accurate descriptions of IASCC susceptibility in this case. A decreased strain localization along grain boundaries, caused by dislocation channel broadening, was confirmed to suppress crack initiation. A unique distribution of irradiation-induced defects in HIP AM 316 L SS eased dislocation cross-slip compared to those in the wrought counterpart, thus increasing the channel width near the grain boundaries. Here for the first time, this study highlights the importance of dislocation channel broadening as a potential mechanism to further improve the IASCC resistance of 316 L SS and provides direct experimental evidence based on commercial-grade materials.

316L stainless steel↗
DOE OSTI2024

Atomistic simulations to reveal HIP-bonding mechanisms of Al6061/Al6061

Molecular dynamics simulations were employed to understand the diffusion bonding process during hot isostatic pressing (HIP) of Al6061/Al6061 alloy. Simulations of the HIP process reveal atomistic phenomena that are difficult or unlikely to be observed experimentally and provide useful insights into the mechanism of diffusion and bonding. Here, the results reveal that at the start of the HIP process, a massive incursion of oxygen atoms occurs from the pre-existing γ-Al 2 O 3 to the 6061 region across the interphase interface. These oxygen atoms interact with the enriched Mg atom layer present at the existing γ-Al 2 O 3 and 6061 matrix to form a secondary complex Mg 2 Al 2 O 5 phase. Diffusion calculations also show that transport of atoms due to the applied pressure is 4–5 orders of magnitude higher than would occur in the absence of HIP conditions. The Mg 2 Al 2 O 5 phase also provides efficient pathways for the rapid transport of Mg atoms. Because of the higher diffusion coefficients observed for Mg within the phase, Mg atoms can move more swiftly compared to their diffusion within other phases such as γ-Al 2 O 3 . This accelerated mobility facilitates the rapid movement of Mg atoms across the interface, leading to changes in the local composition and the potential growth of the Mg 2 Al 2 O 5 phase.

36 MATERIALS SCIENCE↗