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At least 1,459 records · Page 81
All sourcesNASA NTRSDOE OSTI
DOE OSTI2016

Adsorption of oxygen on low-index surfaces of the TiAl{sub 3} alloy

Method of the projector augmented waves in the plane-wave basis within the generalized-gradient approximation for the exchange-correlation functional has been used to study oxygen adsorption on (001), (100), and (110) low-index surfaces of the TiAl{sub 3} alloy. It has been established that the sites that are most energetically preferred for the adsorption of oxygen are hollow (H) positions on the (001) surface and bridge (B) positions on the (110) and (100) surfaces. Structural and electronic factors that define their energy preference have been discussed. Changes in the atomic and electronic structure of subsurface layers that occur as the oxygen concentration increases to three monolayers have been analyzed. It has been shown that the formation of chemical bonds of oxygen with both components of the alloy leads to the appearance of states that are split-off from the bottoms of their valence bands, which is accompanied by the formation of a forbidden gap at the Fermi level and by a weakening of the Ti–Al metallic bonds in the alloy. On the Al-terminated (001) and (110) surfaces, the oxidation of aluminum dominates over that of titanium. On the whole, the binding energy of oxygen on the low-index surfaces with a mixed termination is higher than that at the aluminum-terminated surface. The calculation of the diffusion of oxygen in the TiAl{sub 3} alloy has shown that the lowest barriers correspond to the diffusion between tetrahedral positions in the (001) plane; the diffusion of oxygen in the [001] direction occurs through octahedral and tetrahedral positions. An increase in the concentration of aluminum in the alloy favors a reduction in the height of the energy barriers as compared to the corresponding barriers in the γ-TiAl alloy.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2019

Microplasticity of Amorphous and Crystallized Fe{sub 78}P{sub 20}Si{sub 2} Alloy

In order to determine the mechanism of plastic deformation, the hardness and local plasticity of amorphous Fe{sub 78}P{sub 20}Si{sub 2} alloy are compared at different stages of its crystallization activated by thermal treatment at 300–750°C or short-term photon treatment with a radiation dose coming to the sample of 10–60 J/cm{sup 2}. The phase composition and structure were investigated by X-ray diffractometry and high-resolution transmission electron microscopy. With the same sequence of structural changes, the crystallization rate under photon treatment is more than two orders of magnitude higher than that under thermal treatment, which indicates the effect of a high rate of input of the process activation energy. The nonmonotonic dependence of the hardness, elastic modulus, and the proportion of plastic strain in the indentation work is found, depending on the annealing temperature or radiation dose received by the sample, as a result of structural changes in the alloy. The local plasticity of the initial alloy and fully crystallized alloy are close in magnitude. Based on the features of the crystal structure of the Fe{sub 3}P phase (the impossibility of the dislocation mechanism of plastic deformation) and assuming that the structural unit (tetrahedral Fe{sub 3}P cluster) of the crystallized and amorphous alloy is identical, a conclusion was formulated about the cluster mechanism of plastic deformation of the amorphous alloy.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2022

The Electrochemical Behavior of As-Prepared Aluminum Alloy A360 Produced by Selective Laser Melting Fabrication with and without a Trivalent Chromium Process Conversion Coating

In this paper, we report on the electrochemical behavior and corrosion resistance of as-prepared aluminum alloy, A360 (AlSi10Mg), fabricated by additive manufacturing, with and without a trivalent chromium process conversion coating. Selective laser melting was the 3D printing process used for the alloy build. The corrosion suppression provided by the coating system was assessed through electrochemical measurements and accelerated degradation testing during a 14-day continuous neutral salt-spray exposure. The results indicate that the conversion coating can be formed by solution pretreating (degreasing and deoxidation) the alloy (X-Z plane perpendicular to the build plane) with its native surface roughness (as-prepared) followed by immersion for 10, 15 or 20 min in the coating bath. All three immersion times provide an equivalent level of corrosion protection to the alloy. The conversion coating suppresses both anodic and cathodic currents, increases the polarization resistance, and provides both anodic and cathodic corrosion protection to the as-prepared alloy. The conversion-coated specimens exhibit good stand-alone corrosion resistance during a 14-day neutral salt-spray exposure with corrosion intensity values (g/m 2 -year) ~10x lower than values for the uncoated, as-prepared alloy specimens.

36 MATERIALS SCIENCE↗
DOE OSTI2025

CALPHAD-based Bayesian optimization to accelerate alloy discovery for high-temperature applications

Two crucial properties influencing the performance of high-temperature alloys are coefficient of thermal expansion (CTE) and phase constitution. It is desirable to have alloys with low CTE, which reduces CTE mismatch with the surface oxide and the likelihood of oxide spallation. Reducing the amount of brittle intermetallic phases such as Sigma (σ) enhances alloy ductility and processability. Here, we propose a multi-objective Bayesian Optimization (BO) model to simultaneously minimize CTE (at an operational temperature of 1150 °C) and T σ (temperature when the Sigma phase completely dissolves in the metal matrix), properties which are obtained from high-throughput CALculation of PHAse Diagrams (CALPHAD). The model successfully identifies several alloys with CTE ≤ 2 × 10 –5 /K and T σ ≤ 500 °C by exploring just 7% of the nickel–chromium–cobalt–aluminum–iron (Ni–Cr–Co–Al–Fe) composition space. Such multi-objective alloy design frameworks can be used to inform additive manufacturing experiments and accelerate alloy discovery for high-temperature energy applications.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Creep and Creep-Fatigue of Alloy 617 Weldments

Alloy 617 is the primary candidate material for the heat exchanger of a very high temperature gas cooled reactor intended to operate up to 950°C. While this alloy is currently qualified in the ASME Boiler and Pressure Vessel Code for non-nuclear construction, it is not currently allowed for use in nuclear designs. A draft Code Case to qualify Alloy 617 for nuclear pressure boundary applications was submitted in 1992, but was withdrawn prior to approval. Prior to withdrawal of the draft, comments were received indicating that there was insufficient knowledge of the creep and creep-fatigue behavior of Alloy 617 welds. In this report the results of recent experiments and analysis of the creep-rupture behavior of Alloy 617 welds prepared using the gas tungsten arc process with Alloy 617 filler wire. Low cycle fatigue and creep-fatigue properties of weldments are also discussed. The experiments cover a range of temperatures from 750 to 1000°C to support development of a new Code Case to qualify the material for elevated temperature nuclear design. Properties of the welded material are compared to results of extensive characterization of solution annealed plate base metal.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2017

Predicting the Oxidation/Corrosion Performance of Structural Alloys in Supercritical CO 2

This project was the first research to address oxidation of alloys under supercritical CO 2 conditions relevant to a semi-open Allam Cycle system. The levels of impurities expected in the CO 2 for typical operation were determined by thermodynamic and mass balance calculations, and a test rig was assembled and used to run corrosion tests at temperatures from 650 to 750°C in CO 2 at 200 bar for up to 5,000h, with and without impurities. Oxidation rates were measured for seven alloys representing high-strength ferritic steels, standard austenitic steels, and Ni-based alloys with higher-temperature capabilities. The very thin, protective scales formed on the high-temperature alloys provided significant challenges in characterization and thickness measurement. The rates of mass gain and scale thickening were possibly slower when oxidizing impurities were present in the sCO 2 , and the scale morphologies formed on the ferritic and austenitic steels were consistent with expectations, and similar to those formed in high-pressure steam, with some potential influences of C. Some surface hardening (possibly due to carbon uptake) was identified in ferritic steels Grade 91 and VM12, and appeared more severe in commercially-pure CO 2 . Hardening was also observed in austenitic steel TP304H, but that in HR3C appeared anomalous, probably the result of work-hardening from specimen preparation. No hardening was found in Ni-base alloys IN617 and IN740H. An existing EPRI Oxide Exfoliation Model was modified for this application and used to evaluate the potential impact of the scales grown in sCO 2 on service lifetimes in compact heat exchanger designs. Results suggested that reduction in flow area by simple oxide growth as well as by accumulation of exfoliated scale may have a major effect on the design of small-channel heat exchangers. In addition, the specific oxidation behavior of each alloy strongly influences the relationship of channel wall thickness to service lifetime.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2025

Develop a new integrated macro→micro←nano (MMN) multiscale modeling framework to optimize high strength aluminum alloys and processes for vehicle light-weighting​

Bending tests provide a means to study plane strain fracture performance of 6000 series aluminum alloys. Metrics from bending tests have been correlated with self-pierce riveting (SPR) performance of a high strength AA6111 automotive aluminum alloy in previous works. Using the ORNL HPC resources, this project developed an innovative macro→micro←nano (MMN) multiscale microstructure-based finite element (FE) code to further understanding of the relationship between microstructure and fracture properties of high-strength 6000-series alloys. This work started with microstructural characterization in both mesoscale and nanoscale and bending performance characterization of AA6111 HS2-T6 alloy at Ford, the MMN framework was applied to this alloy to simulate 3-point VDA bending. From the results of the macro-modeling of 3-point VDA bending, the critical region of fracture was identified, and the region geometry was used to construct the micro-model. The fracture criterion of micron-scale precipitates and aluminum matrix which contains submicron and nano particles (AL-SMP-NP) in the micro-model was calibrated and validated by comparing simulated and measured bending results. With the AL-SMP-NP fracture strain obtained, the fracture strain of Al-matrix containing nano particles (ALNP) will similarly be determined by a submicron scale-model using an edge-constrained FE modeling approach developed by Hu et al. With the ALNP fracture strain obtained, the fracture strain of Al-matrix containing no particles will similarly be determined by a nano scale-model using an edge-constrained FE modeling approach. After the MMN framework is built and fracture criterion calibrated, nano-model FE simulations with virtual microstructures was performed to obtain a reduced order model (ROM) of the fracture criterion of the ALNP as a function of volume fraction, size, and distribution of the nanoparticle. This nano→submicron→micro modeling part allows exploration of the influence of different material nanostructures from different process conditions on the bending properties within the multiscale bending simulation framework and the ROM of material bendability as a function of nanoparticle size and shape was established. This obtained reduced order model (ROM) could help guide the design and selection of materials to improve existing SPR process models that could replace trial-and-error rivet/die selection and help to design new rivet/die combinations capable of robustly joining new higher strength 6000 5 series alloys in automotive body structures. This would enable lightweighting of Ford vehicles leading to greater fuel efficiency and reduce manufacturing time and energy.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Assessing Strain Rate Sensitivity of Nanotwinned Al–Zr Alloys through Nanoindentation

Nanotwinned metals have exhibited many enhanced physical and mechanical properties. Twin boundaries have recently been introduced into sputtered Al alloys in spite of their high stacking fault energy. These twinned Al alloys possess unique microstructures composed of vertically aligned Σ3(112) incoherent twin boundaries (ITBs) and have demonstrated remarkable mechanical strengths and thermal stability. However, their strain rate sensitivity has not been fully assessed. A modified nanoindentation method has been employed here to accurately determine the strain rate sensitivity of nanotwinned Al–Zr alloys. The hardness of these alloys reaches 4.2 GPa while simultaneously exhibiting an improved strain rate sensitivity. The nanotwinned Al–Zr alloys have shown grain size-dependent strain rate sensitivity, consistent with previous findings in the literature. This work provides insight into a previously unstudied aspect of nanotwinned Al alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2022

TiNi-Based Bi-Metallic Shape-Memory Alloy by Laser-Directed Energy Deposition

In this study, laser-directed energy deposition was applied to build a Ti-rich ternary Ti–Ni–Cu shape-memory alloy onto a TiNi shape-memory alloy substrate to realize the joining of the multifunctional bi-metallic shape-memory alloy structure. The cost-effective Ti, Ni, and Cu elemental powder blend was used for raw materials. Various material characterization approaches were applied to reveal different material properties in two sections. The as-fabricated Ti–Ni–Cu alloy microstructure has the TiNi phase as the matrix with Ti2Ni secondary precipitates. The hardness shows no high values indicating that the major phase is not hard intermetallics. A bonding strength of 569.1 MPa was obtained by tensile testing, and digital image correlation reveals the different tensile responses of the two sections. Differential scanning calorimetry was used to measure the phase-transformation temperatures. The austenite finishing temperature of higher than 80 °C was measured for the Ti–Ni–Cu alloy section. For the TiNi substrate, the austenite finishing temperature was tested to be near 47 °C at the bottom and around 22 °C at the upper substrate region, which is due to the repeated laser scanning that acts as annealing on the substrate. Finally, the multiple shape-memory effect of two shape-memory alloy sides was tested and identified.

36 MATERIALS SCIENCE↗
NASA NTRS1967

Development of Coatings for Tantalum Alloy Nozzle Vanes

A group of silicide coatings developed for the T222 tantalum-base alloy have afforded over 600 hours of protection at 1600 and 2400 F during cyclic exposure in air. These coatings were applied in two steps. A modifier alloy was applied by slurry techniques and was sintered in vacuum prior to siliciding by pack cementation in argon. Application of the modifier alloy by pack cementation was found to be much less effective. The addition of titanium and vanadium to molybdenum and tungsten yielded beneficial modifier alloys, whereas the addition of chromium showed no improvement. After siliciding, the 15Ti- 35W-15V-35Mo modifier alloy exhibited the best performance; one sample survived 1064 hours of oxidation at 2400 F. This same coating was the only coating to reproducibly provide 600 hours of protection at both 1600 and 2400 F; in the second and third of three experiments, involving oxidation of three to five specimens at each temperature in each experiment, no failures were observed in 600 hours of testing. The slurry coatings were also shown to protect the Cb752 and D43 columbium-base alloys.

PROTECTIVE COATING↗
NASA NTRS2017

Magnesium Alloys for Space Hardware Design

There have been advances in magnesium alloy development that NASA has not taken into consideration for space hardware because of a lack of test data. Magnesium alloys offer excellent weight reduction, specific strength, and deep space radiation mitigation. Traditionally, magnesium has been perceived as having too poor of a flammability resistance and corrosion resistance to be used for flight. Recent developments in magnesium alloying has led to the formation of two alloys, WE43 and Elektron 21, which are self-extinguishing and significantly less flammable because of their composition. Likewise, an anodizing process called Tagnite was formulated to deter any concern with galvanic and saltwater corrosion. The Materials Science Branch at Kennedy Space Center is currently researching these new alloys and treatments to better understand how they behave in the harsh environment of space. Successful completion of the proposed testing should result in a more thorough understanding of modern aerospace materials and processes, and possibly the permission to use magnesium alloys in future NASA designs.

microstructure↗
DOE OSTI2015

Development of Cast Alumina-forming Austenitic Stainless Steel Alloys for use in High Temperature Process Environments

There is significant interest in the development of alumina-forming, creep resistant alloys for use in various industrial process environments. It is expected that these alloys can be fabricated into components for use in these environments through centrifugal casting and welding. Based on the successful earlier studies on the development of wrought versions of Alumina-Forming Austenitic (AFA) alloys, new alloy compositions have been developed for cast products. These alloys achieve good high-temperature oxidation resistance due to the formation of protective Al 2 O 3 scales while multiple second-phase precipitation strengthening contributes to excellent creep resistance. This work will summarize the results on the development and properties of a centrifugally cast AFA alloy. This paper highlights the strength, oxidation resistance in air and water vapor containing environments, and creep properties in the as-cast condition over the temperature range of 750°C to 900°C in a centrifugally cast heat. Preliminary results for a laboratory cast AFA composition with good oxidation resistance at 1100°C are also presented.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Texture and microstructure evolution in thermomechanically processed Mg-Ca and Mg-Zn-Ca alloys

Mg-Zn-Ca alloys have the potential for producing Mg alloy sheets with weaker basal textures and therefore improved formability. Thermomechanical processing (TMP) also plays a substantial role in determining the final sheet texture. The interplay of these variables, TMP and alloying, complicates comparisons of alloys across the literature. This work systematically explores the texture evolution and recrystallization behavior in Mg-Ca and Mg-Zn-Ca alloys during plane strain compression (PSC) using a Gleeble thermomechanical simulator. It is demonstrated that the basal texture intensity and texture characteristics change significantly during post-deformation annealing, particularly in the ternary alloys. It is also shown that careful selection of the TMP processing variables used during PSC is essential to producing weak textures. In particular, it is important to limit the recrystallization that occurs between compressive hits. This is achieved by adjusting solute content, strain rate, and the duration of the soak between passes.

36 MATERIALS SCIENCE↗
DOE OSTI2016

In-situ ion irradiation of ZIRLO alloy

As an alternative to in-core neutron irradiations which are lengthy and costly, ex-core irradiations with energetic ions are envisioned as a possible way to probe the irradiation response of zirconium alloys used in pressurized water reactors (PWRs). Such ion irradiations, being well-controlled experiments, could offer a powerful, easier, and quicker way to study irradiation induced microstructural changes without remote handling that typically lead to structural component dimensional change (such as irradiation growth). Thus these irradiation experiments could help in the development of advanced dimensionally stable and deformation resistant alloys. For this matter, an initial investigation was performed to determine the feasibility of using ex-core ions to develop irradiation damage typically observed after neutron irradiation in Westinghouse's ZIRLO alloy. In-situ ion irradiations of ZIRLO alloy were conducted at the IVEM-Tandem Facility at Argonne National Laboratory at different dose levels and at different temperatures. The initial goal is to induce radiation damage of similar levels (in terms of dpa) to what develops during in-core neutron irradiation and analyze the potential of using ion irradiation as a substitute for in core neutron irradiation of Zr alloys. To facilitate comparison and convergence to in-core neutron irradiation, samples were ion irradiated in transmission and the amount of dpa developed during the ion irradiation was calculated using monte-Carlo based SRIM code. The TEM observations showed that the ion irradiation induced microstructure consisted of - and -type dislocation loops with the -loops developing at a later stage than the - loops, similarly to irradiation damage typically induced in neutron irradiated zirconium alloys. The study offers promises that heavy ion irradiation could potentially, under well-chosen conditions, be used to simulate neutron irradiation damage in PWRs. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2018

First-Principles Investigation of Equiatomic Quaternary Heusler Alloys NbVMnAl and NbFeCrAl and a Discussion of the Generalized Electron-Filling Rule

Plane-wave pseudo-potential methods based on density functional theory are used to study the electronic structures, magnetic, and half-metallic properties of the equiatomic quaternary Heusler alloys NbVMnAl and NbFeCrAl. Calculated results reveal that NbVMnAl and NbFeCrAl alloys are newly designed half-metallic ferrimagnets with a total magnetic moment (M{sub t}) of 2 μ{sub B}. We found that the Slater-Pauling rule, i.e., the relationship between the M{sub t} and the total number of valence electrons (Z{sub t}) of these two alloys was different. For NbVMnAl alloy, it obeys the M{sub t} = |Z{sub t} − 18| rule. For NbFeCrAl, it satisfies the M{sub t} = |Z{sub t} − 24| rule. Also, we observed that the half-metallic band gap (HM-BG) of these two alloys was different. Namely, for one material (NbFeCrAl), it is located in the spin-up channel, and in the other (NbVMnAl), it is located in the spin-down channel. To explain these phenomena, in this work, the generalized electron-filling rule was investigated, and the origin of the HM-BG of NbVMnAl and NbFeCrAl was studied. We hope that our work may provide theoretical guidance in searching for Nb-based equiatomic quaternary Heusler half-metals in the future.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2018

Thermodynamic Properties of Magnesium-Boron Binary Alloys Determined Using Solid-State Electrochemical Measurements

This study provides the thermodynamic properties of the Mg-B binary alloys. Experiments were performed to measure the electromotive force (emf) as a function of temperature (773 K to 873 K) using a solid-state electrochemical cells that can be represented as (−)Pt,Ar/{Mg+CaF_2⋅MgF_2}∥CaF{sub 2}∥{Mg(alloy)+CaF_2⋅MgF_2}/Ar,Pt(+)The activities of Mg in Mg-B alloys were calculated from the experimental emf data. The activity coefficients of Mg in Mg-B alloys were also determined. The integral Gibbs energies of formation (∆G{sub f}{sup °}) of alloys were calculated from the activities of the Mg using tangent rule. The integral Gibbs energies of formation (∆G{sub f}{sup °}) of MgB{sub 2}, MgB{sub 4}, and MgB{sub 7} are − 15.48, − 22.03, and − 15.89 kJ/mol-atoms at 873 K.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Portevin-Le Chatelier mechanism in face-centered-cubic metallic alloys from low to high entropy

Serration phenomena during tensile testing on certain alloys with diffusing solute atoms (i.e., Portevin–Le Chatelier effect) have been observed for a long time, but detailed mechanisms are not fully clear yet. This study is intended to find the mechanism from different approaches verified by tensile testing on a series of single-phase face-centered-cubic (FCC) pure metal and alloys: Ni, CoNi, CoFeNi, CoCrFeNi, and CoCrFeMnNi, which range from low to high configurational entropy. The results of tensile tests, at strain rates from 1 × 10 -5 to 1 × 10 -2 /s and temperature from room temperature to 700 °C, show that serrations occur on stress-strain curves of CoFeNi, CoCrFeNi, and CoCrFeMnNi alloys in their specific temperature and strain-rate regime. A mechanism for dislocation pinning is proposed and verified with theoretical calculation for the present substitutional alloys. The proposed mechanism involves the in-situ rearrangement of substitutional solute atoms by “local dislocation-core diffusion” and might also be applied to similar substitutional alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2016

The microstructure of the surface layer of magnesium laser alloyed with aluminum and silicon

The surface layer under analysis was formed as a result of diffusion bonding of a thin AlSi20 plate to a magnesium substrate followed by laser melting. Depending on the process parameters, the laser beam melted the AlSi20 plate only or the AlSi20 plate and a layer of the magnesium surface adjacent to it. Two types of microstructure of the remelted layer were thus analyzed. If the melting zone was limited to the AlSi20 plate, the microstructure of the surface layer was typical of a rapidly solidified hypereutectic Al–Si alloy. Since, however, the liquid AlSi20 reacted with the magnesium substrate, the following intermetallic phases formed: Al{sub 3}Mg{sub 2}, Mg{sub 17}Al{sub 12} and Mg{sub 2}Si. The microstructure of the modified surface layer of magnesium was examined using optical, scanning electron and transmission electron microscopy. The analysis of the surface properties of the laser modified magnesium revealed that the thin layer has a microstructure of a rapidly solidified Al–Si alloy offering good protection against corrosion. By contrast, the surface layer containing particles of intermetallic phases was more resistant to abrasion but had lower corrosion resistance than the silumin type layer. - Highlights: •A CO{sub 2} laser was used for surface alloying of Mg with AlSi20. •Before alloying, an AlSi20 plate was diffusion bonded with the Mg substrate. •The process parameters affected the alloyed layer microstructure and properties. •With melting limited to AlSi20, the layer had a structure of rapidly solidified AlSi20. •Mg–Al and Mg–Si phases were present when both the substrate and the plate were melted.

36 MATERIALS SCIENCE↗