Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Microstructural evolution”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 1,531 records · Page 85

Genetic programming for interpretable, data-driven continuum damage models.

The damage mechanisms that lead to failure in engineering alloys have been studied extensively, but converting this knowledge into constitutive models that are suitable for engineering-scale analysis remains a challenge. Evolution laws for continuum damage have been developed in the past and have proven effective but suffer from many non-physical assumptions that inhibit the overall accuracy of the model. Further, the assumptions inherent in these existing models prevent them from being applicable to a broad class of materials. At the same time, computational models of fine-scale damage mechanisms continue to advance making it tractable to generate large training data sets through computer simulation. Data-driven machine learning approaches can leverage these data sets to avoid making limiting assumptions, and instead produce models directly from the results of microstructural simulations and/or experiments. Many of these machine learning approaches are rapid and accurate, but they offer little to no insight into the underlying relationships among state variables being discovered. Conversely, genetic programming symbolic regression (GPSR) is a machine learning method that produces analytic expressions relating the state variables, allowing maximal insight and interpretability. To that end, we propose using GPSR as a data-driven method of obtaining microstructurally informed continuum damage models. Data is generated using microstructural simulations of damage evolution, parameterized over microstructural statistics (i.e., pore shape) and nominally applied deformations. Analytic expressions for damage evolution are obtained from the data using GPSR, and these expressions are then utilized within a continuum constitutive model. Overall, this approach is a promising method of automatically obtaining analytic relations describing constitutive phenomena in a material.

Buche, Michael Robert↗

Precipitation behavior of ωo phase and texture evolution of a forged Ti-45Al-8.5Nb-(W, B, Y) alloy during creep

Highlights: • The morphology of ω{sub o} and residual β{sub o} phases depends on creep temperature and stress. • Stress can increase the tendency of the α{sub 2} to ω{sub o} phase transformation. • The strength of the texture components depend on temperature and stress. • β{sub o}(ω{sub o}) precipitation retards the growth of recrystallized γ grains. • ω{sub o} precipitation resists and deflects the crack during the crack propagation. - Abstract: Creep rupture tests of the as-forged Ti-45Al-8.5Nb-(W,B,Y) alloy with a duplex microstructure were carried out at 750–850 °C and 130–300 MPa. An investigation was performed to study the effects of temperature and stress on the microstructure and texture evolution, as well as on the creep properties of the forged high Nb-containing TiAl alloy with a duplex microstructure. The results show that the stress exponent n = 2.8–3.3, and the creep activation energy values are in the range of 300–400 kJ/mol. After creep, a regular arrangement of ω{sub o} precipitations was observed in the β{sub o} region. The un-transformed β{sub o} phase, which remained in the ω{sub o} interval, was examined using high resolution transmission electron microscope (HRTEM). It is shown that the growth of ω{sub o} precipitations and the morphology of residual β{sub o} phases are related to the creep temperature and stress. Certain β{sub o} stabilizer elements, such as Nb, segregate into α{sub 2} plates and cause ω{sub o} precipitation during dissolution of α{sub 2} plates at high temperature. The interfacial structure between the ω{sub o} and α{sub 2} phases was studied in detail using HRTEM. Meanwhile, texture evolution and dynamic recrystallization of the γ phase were studied using electron backscatter diffraction (EBSD). Observations on the deformation structure also demonstrate that ω{sub o} precipitation acts as an obstacle inhibiting crack propagation and growth of the γ phase. The corresponding formation mechanism and possible effects on creep are discussed.

36 MATERIALS SCIENCE↗

Nanostructure formation during accumulative roll bonding of commercial purity titanium

In this investigation, commercial purity titanium (CP–Ti) was subjected to accumulative roll bonding (ARB) process up to 8 cycles (equivalent strain of 6.4) at the ambient temperature. Transmission electron microscopy (TEM) and X–ray diffraction line profile analysis (XRDLPA) were utilized to investigate the microstructure and grain size evolution. Both characterization techniques could clarify the non–uniform microstructure in the early stages and the uniform microstructure in the final stages of the process. The effectiveness of ARB for the fabrication of the nano–grained structure in CP–Ti was revealed. It was found that the SFE is not the only factor affecting grain refinement, as compared with other studies on ARB of FCC materials. Influence of other factors such as the melting temperature and the crystalline structure of the material was determined on the grain refinement. - Highlights: •Nano–grained commercial purity titanium was produced by accumulative roll bonding. •TEM and XRDLPA were used for the characterization of the microstructure. •Important factors affecting the grain size of ARBed materials were discussed.

36 MATERIALS SCIENCE↗

Microstructure and Mechanical Properties of Copper Billets Fabricated by the Repetitive Extrusion and Free Forging Process

In the present study, with the aim of obtaining a weakened texture, grain refinement and improved mechanical properties, copper billets were successfully fabricated using the severe plastic deformation method of repetitive extrusion and free forging (REFF) without using any additional tools or devices. The evolution of the microstructure, texture and mechanical behavior of the ultrafine grain copper billets over an increasing number of REEF cycles was also systematically studied. Our results show that the effective strain per REFF process was ε = 2.35. After two cycles of REFF process, the sum effective strain became ε = 4.7, leading to high efficiency of grain refinement. The grain size was refined from 50 to 0.8 μm; the yield strength was increased to 462 MPa, and we obtained a weakened texture in the pure copper billets. By increasing the number of cycles, the grain refinement ability was decreased, and the texture was thus strengthened further. Therefore, two cycles of REFF were a reasonable process for producing ultrafine-grained copper billets.

36 MATERIALS SCIENCE↗

Crack Initiation Behavior of Cold-Worked Alloy 690 in Simulated PWR Primary Water - Role of Starting Microstructure, Applied Stress and Cold Work on Precursor Damage Evolution

Long-term stress corrosion crack (SCC) initiation behavior in Alloy 690 is being evaluated by constant load tensile testing in simulated pressurized water reactor primary water. Seven commercial Alloy 690 heats with different starting microstructures and cold-work levels are being tested at either 90% or 100% of the material yield stress. Previous studies have revealed grain boundary (GB) cavity formation after 7,110 to 9,220 hours of exposure in certain thermally treated (TT) Alloy 690 heats in highly cold-worked (CW) conditions, serving as precursors to intergranular cracks. This paper summarizes the new characterization results for the evolution of GB cavities in four Alloy 690TT heats in 21% and 31%CW conditions loaded at yield stress after 18,400 hours of exposure. Link-up of GB cavities has led to formation of long internal creep cracks, resulting in crack initiation detected by direct current potential drop in a highly CW Alloy 690TT heat with uniform, semi-continuous distribution of small GB carbides. In comparison, highly CW materials featuring larger and more widely spaced GB carbides did not show a significant increase in GB cavity density or size. Quantitative assessments were performed on GB cavity evolution in highly CW specimens for two Alloy 690TT heats demonstrating the strong dependence of GB cavity evolution on applied stress and starting GB microstructure.

Zhai, Ziqing↗

Friction stir welding and self-ion irradiation effects on microstructure and mechanical properties changes within oxide dispersion strengthened steel $\mathrm{MA956}$

We report the joining process for oxide dispersion strengthened (ODS) alloys remains a key challenge facing the nuclear community. The microstructure and mechanical properties were characterized in the base material and friction stir welded ODS MA956 irradiated with 5 MeV Fe 2+ ions from 400 to 500°C up to 25 dpa. Nanoindentation was performed to assess changes in hardness and yield stress, and the dispersed barrier hardening (DBH) model was applied to described results. A combination of scanning transmission electron microscopy (STEM) and atom probe tomography (APT) were used to assess evolution of the microstructure including dispersoids, network dislocations and dislocation loops, nanoclusters, and solid solution concentrations. Overall, softening was observed as a result of increased dose, which was exacerbated at 500°C. The formation and coarsening of new dispersoids was noted while nanoclusters tended to dissolve in the base material, and were not observed in the stir zone. Solute nanocluster evolution was identified as a primary driver of the changes in mechanical properties.

36 MATERIALS SCIENCE↗

Scan strategies in EBM-printed IN718 and the physics of bulk 3D microstructure development

Three-dimensional (3D) characterization provides opportunities for understanding processing-structure relationships in additively manufactured (AM) materials. Bulk samples of Inconel 718 were fabricated via electron beam melting (EBM) in order to study microstructural development as a function of energy input and beam scan strategy. TriBeam tomography of bulk Inconel 718 microstructures built under steady-state growth conditions reveals the sensitivity of microstructure formation and evolution to machine process parameters. Here, samples manufactured using a narrow range of energy input per unit build area result in varied grain morphologies and crystallographic textures. Using TRUCHAS, a thermal simulation software, the thermal history of bulk scan strategies was predicted, and combined with a calibrated microstructure-processing map to accurately predict bulk grain morphologies. The solidification parameters and the 3D measured nucleation density are used to predict the transition between columnar and equiaxed grain morphologies, providing a process map to guide AM parameter choices to locally control as-printed microstructure. A two-dimensional metric for characterizing bulk grain morphology was also found to agree well with predictions from the process map calibrated by 3D data. Combined with 3D tomography and thermal modelling, the physics of structure development were understood at a new level of detail with respect to the competing processes of grain nucleation and epitaxial growth.

36 MATERIALS SCIENCE↗

Viscous Shear Banding in Cutting of Metals

Shear banding is a type of plastic flow instability with often adverse implications for cutting and deformation processing of metals. Here, we study the mechanics of plastic flow evolution within single shear bands in Ti- and Ni-based alloy systems. The local shear band displacement profiles are quantitatively mapped at high resolution using a special micromarker technique. The results show that shear bands, once nucleated, evolve by a universal viscous sliding mechanism that is independent of microstructural details. The evolution of local deformation around the band is accurately captured by a momentum diffusion equation based on a Bingham-type flow rule. The predicted band viscosity is very small, compared to those of liquid metals. A plausible explanation for this small viscosity and fluid-like behavior at the band, based on phonon drag, is presented.

Engineering↗

Neutron irradiation effects on the corrosion of Zircaloy-4 in a pressurized water reactor environment - 2016-0085

Long-time Advanced Test Reactor (ATR) corrosion weight-gain data from non-fueled α-processed Zircaloy-4 cladding coupons are presented herein. The data were generated in pressurized loops that simulated pressurized water reactor (PWR) chemistry, temperature, and neutron flux conditions. High neutron flux and high-fluence post-transition corrosion rates were accelerated over out-of-flux post-transition corrosion rates by more than 40 times at 270 deg. C and more than 30 times at 310 deg. C We conclude in large part that the acceleration was caused by irradiation-induced changes to the base metal. The effect that irradiation has on the base metal and its effect on corrosion has been shown in the past to be carried over into post-irradiation tests in autoclave environments, but its impact was shown in this study to be accentuated in the in-reactor environment, in which sustained corrosion accelerations were much greater than observed in the postirradiation tests (in non-irradiation environments). This suggests some aspect of the radiation environment potentially acts synergistically with the corrosion film formed from the irradiation-damaged base metal to further accelerate in-reactor corrosion rates. We also present results from detailed microstructural examinations of thick (more than 25 μm) oxide films formed on α-processed Zircaloy-4 grown in a 360 deg. C autoclave and in the reactor. The examinations consisted of optical microscopy, field emission gun scanning electron microscopy, focused ion beam microscopy, analytical electron microscopy, and X-ray diffraction, with a focus on the evolution of the microstructure of the intermetallic precipitates in the oxide films during exposure to autoclave water or to the corroding environment under neutron irradiation. The film microstructure suggests that the water environment was closer to the oxide-metal interface in the films grown in the reactor than in the autoclave-grown corrosion films examined, but it was not obvious from the microstructural examinations how the radiation environment facilitated that effect. (authors)

36 MATERIALS SCIENCE↗

Bulk nanocrystalline Al–Mg–Y alloys with amorphous grain boundary complexions display high strength and compressive plasticity

Although nanocrystalline alloys regularly exhibit high strengths, their use in structural applications often face challenges due to sample size limitations, unstable microstructures, and the limited ability to plastically deform. The incorporation of amorphous grain boundary complexions has been proposed to address these issues, by simultaneously stabilizing nanocrystalline grain structures for scale-up processing and improving alloy toughness. In the present study, the mechanical behavior of bulk nanocrystalline Al–Mg–Y is examined with macroscale compression testing, probing a length scale that is relevant to real-world structural applications. Bulk samples were fabricated via a simple powder metallurgy approach, with different hot-pressing temperatures and durations employed for consolidation in order to investigate microstructural and property evolution. All of the specimens contained primary face-centered cubic Al and secondary Al 4 C 3 and Al 3 Y phases, with the Al 3 Y particles exhibiting two populations of small equiaxed and larger elongated particles. Appreciable plasticity was measured along with high ultimate stresses over 800 MPa due to the presence of amorphous grain boundary complexions. Microstructural characterization of fracture surfaces revealed that the area fraction of dimpled regions increased with longer hot-pressing time. Most importantly, the elongated Al 3 Y particles formed regular cellular patterns with increasing hot-pressing time, delaying shear localization and significantly enhancing plasticity. The hierarchy present in the microstructure of the Al–Mg–Y alloy, from amorphous grain boundary complexions to secondary phases, gives rise to excellent bulk mechanical properties, which are attractive for structural applications.

Bulk nanocrystalline alloy↗

Defect evolution in single crystalline tungsten following low temperature and low dose neutron irradiation

The tungsten plasma-facing components of fusion reactors will experience an extreme environment including high temperature, intense particle fluxes of gas atoms, high-energy neutron irradiation, and significant cyclic stress loading. Irradiation-induced defect accumulation resulting in severe thermo-mechanical property degradation is expected. For this reason, and because of the lack of relevant fusion neutron sources, the fundamentals of tungsten radiation damage must be understood through coordinated mixed-spectrum fission reactor irradiation experiments and modeling. In this study, high-purity (110) single-crystal tungsten was examined by positron annihilation spectroscopy and transmission electron microscopy following low-temperature (~90 °C) and low-dose (0.006 and 0.03 dpa) mixed-spectrum neutron irradiation and subsequent isochronal annealing at 400, 500, 650, 800, 1000, 1150, and 1300 °C. The results provide insights into microstructural and defect evolution, thus identifying the mechanisms of different annealing behavior. Following 1 h annealing, ex situ characterization of vacancy defects using positron lifetime spectroscopy and coincidence Doppler broadening was performed. The vacancy cluster size distributions indicated intense vacancy clustering at 400 °C with significant damage recovery around 1000 °C. Coincidence Doppler broadening measurements confirm the trend of the vacancy defect evolution, and the S–W plots indicate that only a single type of vacancy cluster is present. Furthermore, transmission electron microscopy observations at selected annealing conditions provide supplemental information on dislocation loop populations and visible void formation. This microstructural information is consistent with the measured irradiation-induced hardening at each annealing stage. This provides insight into tungsten hardening and embrittlement due to irradiation-induced matrix defects.

Hu, Xunxiang↗

Effect of annealing after strip casting on microstructure, precipitates and texture in non-oriented silicon steel produced by twin-roll strip casting

Highlights: • Non-oriented silicon steel with superior magnetic properties was produced by twin-roll strip casting. • The effect of annealing after strip casting on microstructure, precipitates and texture was investigated. • Role of precipitates in microstructure and texture evolution along the entire route was explored. • High magnetic induction and strong λ-fiber texture was obtained by optimizing strip annealing process. - Abstract: A 3.1 mm thick non-oriented Fe-1.0% Si steel as-cast strip was produced by twin-roll strip casting. Samples with/without strip annealing were cold rolled to 0.5 mm and then annealed. The development of microstructure, precipitate and texture was characterized along the entire processing route. It was found that annealing after strip casting had a minor influence on the average grain size and texture of the as-cast strip. A large number of particles precipitated and coarsened during the strip annealing process. Meanwhile, precipitates hindered dislocation slip and crystal rotation such that more significant in-grain shear bands were formed in cold rolled sheets. During recrystallization annealing process, the newly formed fine precipitates in directly cold-rolled sheets consumed stored strain energy and also hindered grain growth. But the initial precipitates in the annealed strip grew further and the effect of pinning of dislocations and grain boundary was lost. Therefore, annealed sheets with strip annealing process showed homogeneous equiaxed grains and the recrystallization texture was characterized by strong λ-fiber texture, which led to high permeability.

36 MATERIALS SCIENCE↗

Texture evolution and their effects on the mechanical properties of duplex Mg-Li alloy

Texture evolution is strongly dependent on the deformation mode during thermo-mechanical treatments. In this paper, we report the texture evolution in a duplex Mg-Li alloy. The results provide an evidence of deformation mode transition in the hexagonal-close-packed (hcp) alpha phase with various thickness reductions. The activation sequence of deformation modes is basal slip first, and then pyramidal slip during hot-rolling to a thickness reduction of 40%. The relative activity of slip decreases with further thickness reduction. After annealing, basal texture is strengthened and pyramidal component disappears due to static recrystallization and grain growth. The microstructure, specifically texture evolution in both hcp alpha and body-centered cubic (bcc) beta phase and their effects on mechanical properties are quantitatively analyzed and assessed. (C) 2016 Elsevier B.V. All rights reserved.

36 MATERIALS SCIENCE↗

Microstructural and phase changes in alpha uranium investigated via in-situ studies and molecular dynamics

A deeper knowledge of thermally induced microstructural and phase evolution in nuclear metallic fuel can be obtained using novel in-situ microscopic analyses. Such studies can provide information on the dynamics of phase transitions which is not possible with conventional postmortem characterization (post-irradiation examination). In this work, the behavior of alpha uranium (α-U) was investigated via in-situ heating tests in a transmission electron microscope. Here, the main objective is to understand the microstructural and phase changes, such as defect annihilation and ß phase formation and retention, observed in reactor in-pile transient studies at the Transient Reactor Test facility. Indeed, defect migration and rearrangement were observed within the α phase starting at 673 K; α→ß phase transition was observed between 773 K and 1,073 K during the heating ramp (which is in the temperature window reported for α→ß transition temperatures). Recrystallization and formation of nano grains was observed at high temperatures (over 1,073 K). Such recrystallization was possibly related to the formation of the γ phase. Finally, it was indeed observed that the ß phase (but not γ phase) was retained at room temperature upon rapid cooling. Molecular dynamics studies support these experimental results and shows that the γ phase of pure uranium cannot be retained at room temperature if not stabilized with the addition of an alloying element.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Microstructure, Texture, and Mechanical Properties of Continuously Extruded and Rolled AZ31 Magnesium Alloy Sheets

It is difficult to fabricate magnesium alloy sheets at room temperature due to their hexagonal close-packed structure. In this paper, we proposed a new process that can be used to fabricate AZ31 magnesium alloy sheets with fine-grained microstructure and good mechanical properties. AZ31 magnesium alloy sheets with dimensions of 160 mm × 8 mm were obtained successfully by a continuous extrusion technique. The extruded sheets were then rolled by two different rolling routes, Route 1: the extruded sheet was heated at 350 °C and then rolled without heating of rolls and Route 2: the sheet was rolled without any previous heating by heating rolls at 280 °C. The microstructure and texture evolution as well as mechanical properties of the continuously extruded and rolled sheets were examined experimentally. The magnesium alloy sheets with relatively fine grains of 4.5-8.3 µm were obtained by continuous extrusion followed by rolling processes. The tensile strength of continuously extruded AZ31 Mg alloy sheets can be effectively increased by rolling using heating rolls (Route 2), while the ductility was enhanced by rolling heated sheets (Route 1). The mixed microstructure, consisting of refined DRX grains and deformed grains, contributes to enhancement in tensile strength of the sheet samples rolled by Route 2 due to grain-boundary strengthening and work hardening. Lower temperature and larger rolling reduction are two main factors for improving the tensile strength of AZ31magnesium alloy sheets.

36 MATERIALS SCIENCE↗

Effect of as-cast microstructure heterogeneity on aging behavior of a high-pressure die-cast A380 alloy

Highlights: • The surface layer hardened much faster than the central region during age. • More quantity of finer precipitates was found in the surface layer during age. • The surface layer had a lower activation energy of precipitation. • Si promoted the precipitation via inducing dislocations in matrix. - Abstract: Microstructure and hardness evolution of a vacuum-assistant die-cast A380 alloy during heat treatment were investigated. Both surface layer and central region of the casting component were analyzed in die-cast state, solutionized state and artificial age state. During the artificial age, the surface layer hardened more significantly than the central region due to faster precipitation and more refined hardening phases in the surface layer. Detailed analysis on the macro-segregation, microstructure morphology and grain size revealed that the different aging behaviors exhibiting in the surface and the central region were mainly attributed to a combining effect of the enrichment of Si and Cu at the surface layer, the fully-divorced morphology of eutectic in die-cast microstructure, and the presence of the externally solidified crystals at the central region. The presence of the Si particles, which exhibited quite different thermal expansion properties, changed the density and the distribution of the dislocations in the α-Al matrix, and consequently changed the precipitation of the hardening phases.

36 MATERIALS SCIENCE↗

ZrN coating as diffusion barrier in U(Mo) dispersion fuel systems

The control of the interaction between the U(Mo) fuel phase and the Al matrix is one of the challenges of dispersion fuel plate development for research reactors. Given the specific properties of this interaction layer, larger amounts of it in the meat could lead to a reduction of the plate mechanical integrity and thermal conductivity, eventually leading to pillowing. The SELENIUM project showed that by depositing a ZrN coating on the surface of the U(Mo) fuel particles, the amount of formed U(Mo)-Al interaction layer is limited but still present. Microstructural analysis performed on the as fabricated coating and fresh fuel plates containing ZrN coated U(Mo) dispersed in an Al matrix, revealed that the coating gets damaged during plate production. The post irradiation examinations (PIE) of the ZrN coated U(Mo) fuel plates, from the SELENIUM and SEMPER FIDELIS experiments, show how the U(Mo)-Al interaction layer is formed -only at those locations where the coating is missing or damaged -and the evolution of coating microstructure during irradiation. Finally, as a remedy, to further reduce the amount of interaction layer formed, the use of an Al-Si matrix was proposed based on the higher affinity of Si for U compared to the affinity of Al for U. PIE of a fuel plate consisting of ZrN coated U(Mo) dispersed in an Al-Si matrix irradiated in the SEMPER FIDELIS experiment, clearly demonstrates the benefit of adding Si to the matrix.

36 MATERIALS SCIENCE↗

Characterization of Subsurface Microstructural Alterations Induced by Hard Turning of Inconel 718

Conventional machining especially hard turning is commonly used in aerospace industry to produce the final shape of cylindrical parts. However, the process generates damages and microstructural alterations on the surface and at the subsurface layer, in particular the cracking of hard carbides particles. The present paper focuses on investigating the probable mechanisms responsible for carbide cracking and the formation of a softened layer at a depth between 10 and 30 µm below the machined surface. Advanced techniques, such as laser confocal microscopy and field emission gun scanning electron microscope equipped with in situ picoindenter and electron backscatter diffraction, were used to characterize and analyze the evolution of the microstructure in the affected layer and propose the possible governing mechanisms for the observations.

36 MATERIALS SCIENCE↗