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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 1,549 records · Page 86
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Material properties and mechanical behaviour of functionally graded steel produced by wire-arc additive manufacturing

Metal Big Area Additive Manufacturing is an additive manufacturing technique based on Gas Metal Arc Welding (GMAW) with the option to use many shielding gases, and materials. The system is equipped with a dual torch design allowing for printing different materials; in our study, AISI 410 stainless steel and AWS ER70S-6 mild steel are both printed in the same component. Different print strategies were designed to highlight changes in material and mechanical properties. Deformation behaviour of a materials’ interface was analysed by two-dimensional digital image correlation of uniaxial tensile specimens in displacement-controlled tests. Instances of non-homogeneous local strains adjacent to the interface are observed, as well as variability in mechanical behaviour and microstructure based on location within the print. Optical and electron microscopy are used to evaluate three microstructural zones in a 5 mm range of the interface between mild steel and stainless steel. Areas far from the interface produced polygonal ferrite and pearlite, while areas close to the interface produced acicular ferrite and bainite. Chromium redistribution profiles are dependent on the print strategy used, as shown by scanning electron microscopy with Energy dispersive spectroscopy. Evidence produced via electron backscatter diffraction is shown to support the argument that transformation induced plasticity is not the cause for the non-homogeneous deformation.

36 MATERIALS SCIENCE↗
DOE OSTI2015

From Bessel beam to complex-source-point cylindrical wave-function

This investigation shows that a scalar Bessel beam can be transformed into the non-paraxial complex-source-point cylindrical wave (CSPCW). High-order CSPCW solutions, termed here high-order quasi-Gaussian cylindrical beams, which exactly satisfy the Helmholtz equation, are derived analytically. Moreover, partial-derivatives of the high-order CSPCW solutions satisfy the Helmholtz equation. In addition, the CSPCW solutions satisfy the nonrelativistic Schrödinger equation within standard quantum mechanics, thus, the results can be used in the description of elementary particle/matter motion and related applications in quantum scattering theory. Furthermore, the analysis is extended to the case of vector beams in which the components of the electromagnetic (EM) field are obtained based on different polarizations of the magnetic and electric vector potentials, which exactly satisfy Maxwell’s vectorial equations and Lorenz’ gauge condition. An attractive feature of the high-order solutions is the rigorous description of strongly focused (or strongly divergent) cylindrical wave-fields without any approximations, nor the need for numerical methods. Possible applications are in beam-forming design using high-aperture or collimated cylindrical laser/electron quasi-Gaussian beams in imaging microscopy, particle manipulation, optical tweezers, and the study of the scattering, and radiation forces on objects. - Highlights: • Bessel beam is transformed into the non-paraxial cylindrical complex-source-point. • Exact high-order tightly focused solutions are derived without any approximations. • The exact solutions also satisfy the nonrelativistic Schrödinger equation. • Electromagnetic beams are obtained as solutions of Maxwell’s vectorial equations. • Applications are in laser/electron beam imaging, tweezers, and radiation force.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2019

Bulk single crystal growth and sample surface preparation of catalytic NaAu 2

Here in we have grown bulk single crystals of NaAu 2 for the first time to enable surface studies on the nature of the (111) bulk surface. This intermetallic compound exhibits surprisingly high catalytic activity for CO oxidation, a benchmark reaction. Theory predicts NaAu 2 to be the most thermodynamically stable composition in the Na-Au binary phase diagram and NaAu 2 has been seen to preferentially form in experiments containing Na and Au which supports this prediction. The (111) surface was also predicted to be the most stable and is nearly bulk-terminated making single crystal samples prepared with this crystallographic orientation a fitting choice. As a result, the crystal quality and surface composition of the metallographically prepared surface was determined by x-ray diffraction methods in addition to optical and electron microscopy.

(111) catalytic surface↗
DOE OSTI2022

A process optimization framework for laser direct energy deposition: Densification, microstructure, and mechanical properties of an Fe-Cr alloy

Laser Direct Energy Deposition (DED) is a metal additive manufacturing technique with the ability to fabricate large and complex parts through deposition of metal powders. However, achieving high-density parts and targeted build heights using DED can be challenging due to the large number of highly sensitive process variables. This work proposes a robust fabrication parameter optimization framework to generate process maps for primary parameters in DED, including laser power, scan speed, mass flow rate, hatch spacing, and layer height. Simple single-track experiments were utilized to map out the parameter space, and a combination of geometric criteria for hatch spacing and layer height were proposed to determine parameter sets that achieve both targeted build heights and mitigate porosity formation. Using this framework, specimens with >99 % density and consistent mechanical properties were successfully fabricated over a wide range of process parameters for an Fe-9wt.%Cr (Fe9Cr) alloy, a surrogate for radiation damage-resistant reduced activation ferritic/martensitic (RAFM) steels. Processing these materials using DED is of particular interest in the development of plasma facing components for nuclear fusion applications. The microstructure and mechanical properties of as-printed Fe9Cr were characterized using optical and electron microscopy, X-ray diffraction, and uniaxial tensile tests. As-printed Fe9Cr displayed ~25 % elongation and ultimate tensile strengths of up to 475 MPa which is comparable to similar wrought alloys. Finally, the proposed framework will allow for accelerated DED parameter optimization for novel alloy systems, as well as open the possibility for local microstructure control while simultaneously mitigating defect formation.

42 ENGINEERING↗
DOE OSTI2017

Lamellae spatial distribution modulates fracture behavior and toughness of african pangolin scales

Pangolin scales form a durable armor whose hierarchical structure offers an avenue towards high performance bio-inspired materials design. In this paper, the fracture resistance of African pangolin scales is examined using single edge crack three-point bend fracture testing in order to understand toughening mechanisms arising from the structures of natural mammalian armors. In these mechanical tests, the influence of material orientation and hydration level are examined. The fracture experiments reveal an exceptional fracture resistance due to crack deflection induced by the internal spatial orientation of lamellae. An order of magnitude increase in the measured fracture resistance due to scale hydration, reaching up to ~ 25 kJ/m 2 was measured. Post-mortem analysis of the fracture samples was performed using a combination of optical and electron microscopy, and X-ray computerized tomography. Interestingly, the crack profile morphologies are observed to follow paths outlined by the keratinous lamellae structure of the pangolin scale. Most notably, the inherent structure of pangolin scales offers a pathway for crack deflection and fracture toughening. Finally, the results of this study are expected to be useful as design principles for high performance biomimetic applications.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2018

Production and characterization of TRISO fuel particles with multilayered SiC

Three distinct composite architectures of silicon carbide (SiC) and pyrocarbon (PyC) were incorporated into the SiC coating layer of tristructural-isotropic (TRISO) nuclear fuel particles. The composite architectures are meant to increase the resistance of SiC coating layer to cracking and fission product attack during operation and accident scenarios. All composite layers were produced using the existing fluidized bed chemical vapor deposition apparatus that is used for production of TRISO fuel particles without modifications. Detailed characterization of the composite microstructure was carried out via optical and electron microscopy. Nano-indentation examination confirms that mechanical properties of the SiC phase was not affected in the composite architectures, however, the resistance to crack propagation in this coating layer was greatly increased in all cases when compared to the reference monolithic coating layer. The stress required to debond the SiC-inner PyC interface in the reference TRISO particles was determined to be ~1 GPa using micropillar compression technique. The high strength may explain the ease of crack propagation from the inner PyC to SiC in the reference design. In the composite architectures, the means of crack deflection were effectively incorporated at this interface. Lastly, finite element analysis of stress evolution in the fuel particles during normal operation with the reference and composite SiC coating layer architectures did not show any significant differences between the variants.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2017

Fragmentation of copper current collectors in Li-ion batteries during spherical indentation

Large, areal, brittle fracture of copper current collector foils was observed by 3D x-ray computed tomography (XCT) of a spherically indented Li-ion cell. This fracture was hidden and non-catastrophic to a degree because the graphite layers deformed plastically, and held the materials together so that the cracks in the foils could not be seen under optical and electron microscopy. 3D XCT on the indented cell showed “mud cracks” within the copper layer. The cracking of copper foils could not be immediately confirmed when the cell was opened for post-mortem examination. However, an X-ray radiograph on a single foil of the Cu anode showed clearly that the copper foil had broken into multiple pieces similar to the brittle cracking of a ceramic under indentation. This new failure mode of anodes on Li-ion cell has very important implications on the behavior of Li-ion cells under mechanical abuse conditions. Furthermore, the fragmentation of current collectors in the anode must be taken into consideration for the electrochemical responses which may lead to capacity loss and affect thermal runaway behavior of the cells.

25 ENERGY STORAGE↗
DOE OSTI2015

Evolution of weld metal microstructure in shielded metal arc welding of X70 HSLA steel with cellulosic electrodes: A case study

The microstructure of weld joint in X70 line pipe steel resulted from shielded metal arc welding with E6010 cellulosic electrodes is characterized using optical and electron microscopy. A range of ferritic morphologies have been identified ranging from polygonal inter- and intra-prior austenite grains allotriomorphic, idiomorphic ferrites to Widmanstätten, acicular and bainitic ferrites. Electron Backscatter Diffraction (EBSD) analysis using Image Quality (IQ) and Inverse Pole Figure (IPF) maps through superimposition of IQ and IPF maps and measurement of percentages of high and low angle grain boundaries was identified to assist in differentiation of acicular ferrite from Widmanstätten and bainitic ferrite morphologies. In addition two types of pearlitic structures were identified. There was no martensite detected in this weld structure. The morphology, size and chemistry of non-metallic inclusions are also discussed briefly. - Highlights: • Application of EBSD reveals orientation relationships in a range of phases for shielded metal arc welding of HSLA steel. • Nucleation sites of various ferrite morphologies identified • Formation of upper and lower bainite and their morphologies.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Formation and evolution of platelet-like Ti-rich precipitates in the V–4Cr–4Ti alloy

The goal of the present investigation is to explain the obviously different appearances of Ti-rich precipitates in vanadium alloy and in steels. To achieve the goal, the formation and evolution of the precipitates in the as-cast and the heat treated V–4Cr–4Ti samples were investigated using optical and electron microscopies. The precipitates were found to be rare in the as-cast samples, and a high density of the precipitates occur in the samples subjected to isothermal holding at 600–1300 °C. The precipitates preferentially distribute within the grains rather than at the grain boundaries. All of the precipitates are platelet-like, with NaCl structure, in three-dimensional space. The further observation using high-resolution electron microscopy (HREM) reveals that a high density of twins occurs in the growth front of the precipitates, whereas the middle of the precipitates is twin-free. Meanwhile, enrichment of titanium atoms was observed in the middle of the precipitates. These results indicate that the precipitates form by a displacive transformation, followed by a diffusional process to enrich titanium further and eliminate the twined structure. - Highlights: • Precipitates in the V–4Cr–4Ti alloy are Ti-(CN) with NaCl structure. • The Ti-rich precipitates are platelet-like in three dimensional space. • Twins occur in both ends of the precipitates and the midst of these is twin-free. • Twinning and its elimination is explained by displacive followed by diffusion.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Characterization of weld metal microstructure in a Ni-30Cr alloy with additions of niobium and molybdenum

Additions of niobium (Nb) and molybdenum (Mo) were made to an Alloy 690 base alloy in order to investigate the formation of a eutectic constituent at the end of solidification and to evaluate the effect of the eutectic liquid on backfilling (or healing) of solidification cracks. Solidification cracking was induced using the cast pin tear test (CPTT) and regions of backfilling were located and characterized via optical and electron microscopy. Computational predictions of fraction eutectic and composition of the eutectic constituent were compared to experimental findings and were found to correlate well in both cases. The extent of crack backfilling increased significantly with increasing Nb content, but the addition of Mo did not seem to influence the amount of eutectic constituent or the degree of backfilling. SEM/EDS analysis confirmed that the eutectic composition is constant and that increasing Nb above 4 wt% has little effect on expanding the solidification temperature range, but has a beneficial effect on mitigating solidification cracking by a crack healing effect. - Highlights: • Increasing fraction eutectic as a function of Nb, as predicted by ThermoCalc™, is consistent with image analysis results. • Nb, unlike Mo, had a significant effect on the fraction eutectic formed. • Both influence the composition of the eutectic. • Thermocalc™ predictions regarding Nb content in eutectic are consistent with EDS results, but are high for the Mo content. • Increased levels of niobium resulted in a higher degree of crack backfilling and leads to a lower cracking susceptibility. • Mo may influence the eutectic liquid along solidification grain boundaries, improving backfill and thus cracking resistance.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Formation mechanisms of periodic longitudinal microstructure and texture patterns in friction stir welded magnesium AZ80

Many studies of friction stir welding have shown that periodicity of metal flow around the tool pin may result in the formation of periodic differences in microstructure and texture in the weld nugget area correlated with the weld pitch. The current work investigates the periodicity of magnesium weld microtexture in the nugget region and its association with material flow using optical and electron microscopy. Two welds created in AZ80 at different processing conditions are presented in detail, one illustrating periodic longitudinal texture change, and one showing for the first time that periodic variations in texture, grain size, or composition are not defining features of periodic nugget flow. While nugget texture is dominated by shear deformation, it was found here to be affected to a lesser degree by compaction of material behind the welding tool, which led to reduction in intensity of the shear texture fiber. The decreased tendency for magnesium based alloys to form periodic patterns as compared to aluminum based alloys is explained with reference to the shear textures. - Highlights: •It is shown here that periodic material flow in the nugget does not necessitate longitudinal texture patterns. •Longitudinal texture patterns are shown to be present or absent in Mg AZ80 based on processing conditions. •Texture in the nugget is mainly dictated by shear deformation, but has measurable effects from other deformation modes. •Explanation of why longitudinal texture change is frequently reported in aluminum but not magnesium alloys is provided. •A new vector visualization of material flow based on EBSD data analysis is shown.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Microstructure, mechanical properties and microtexture of friction stir welded S690QL high yield steel

Two try-out campaigns of friction stir welding (FSW) were performed with different friction parameters to join S690QL high yield strength steel. The welds were investigated at macroscopic and microscopic scales using optical and electronic microscopy and microhardness mapping. Welds of the second campaign exhibit microstructures and mechanical properties in accordance with requirements for service use. Microtexture measurements were carried out in different zones of welds by electron backscattered diffraction (EBSD). It is shown that that texture of the bottom of the weld is similar to that of the base metal, suggesting a diffusion bonding mechanism. Finally, the mechanical properties (tensile strength, resilience, bending) were established on the most promising welds. It is shown that it is possible to weld this high yield strength steel using FSW process with satisfactory geometric, microstructural and mechanical properties. - Highlights: •1000 mm ∗ 400 mm ∗ 8 mm S690QL steel plates are joined by friction stir welding (FSW). •Maximum hardness is reduced by optimization of process parameters. •Various microstructures are formed but no martensite after process optimization. •Texture is modified in mechanically affected zones of the weld. •Texture in the bottom of the weld is preserved, suggesting diffusion bonding.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Effect of stored strain energy heterogeneity on microstructure evolution of 90% cold rolled AISI 304L stainless steel during interrupted annealing treatment

Highlights: • Study of usefulness of stored strain energy distribution map of the material for variable temperature range. • Advantage of using stored strain energy distribution map • Variation observed in stored energy between isothermal annealing treatment and interrupted annealing treatment. - Abstract: This research work is an attempt to understand the effect of stored strain energy heterogeneity over macro-scale, induced during interrupted annealing treatment, on the micro structural evolution in a heavily cold rolled AISI 304L austenitic stainless steel. The cold rolled AISI 304L stainless steel (SS) samples were subjected to different annealing treatments. The microstructures obtained after each annealing treatment were characterized using optical and electron microscopy techniques. Further, an attempt was made to estimate the stored strain energy by a novel approach of micro hardness measurement both over small scale (area 3600 μm{sup 2}) and large scale (area ~0.25 mm{sup 2}). The stored strain energy was determined using hardness values. Using these data, spatial stored strain energy distribution contour maps were created. They were, in turn, used to characterize the local softening behavior both at micro and macro-scale levels after each interrupted annealing treatment. The results showed that, interrupted annealing treatment induces increased stored strain energy heterogeneity after each annealing interruptions. Also, it was possible to determine recrystallization kinetics of the material using stored strain energy map, which helps in designing annealing cycles for achieving ultrafine grained microstructure.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Austenite stability and M2C carbide decomposition in experimental secondary hardening ultra-high strength steels during high temperature austenitizing treatments

The present study deals with the austenite stability and M{sub 2}C carbide decomposition in three secondary hardening ultra-high strength (SHUHS) steels with varying levels of Cr and Mo (2Cr-1Mo, 2Cr-3Mo and 5Cr-5Mo) investigated using Vicker's hardness, optical and electron microscopy. These steels were subjected to high temperature austenitizing treatments at 1000, 1050, 1100 and 1150 °C. It has been established that increasing both Cr and Mo to 5 wt% as well as increasing the austenitizing temperature in this class of SHUHS steels is stabilizing the austenite such that almost 100% austenite is produced upon oil quenching. Further, higher Cr and Mo is also found to influence the stability of metastable M{sub 2}C carbide formed during processing of the steels. While the M{sub 2}C carbide in 2Cr-3Mo steel remained untransformed, it was found to transform partially to M{sub 6}C during austenitization of 5Cr-5Mo steel. Hardness measurements on these steels revealed that hardness is relatively insensitive to austenitizing temperature in 2Cr-1Mo steel, decreased in 2Cr-3Mo and decreased more drastically in 5Cr-5Mo steel with austenitizing temperature. This dependence has been correlated to the influence of composition on M{sub s} temperature and hence on retention of austenite as well as primary carbides. The experimental results were compared against theoretical calculations using ThermoCalc, which predict the presence of only M{sub 6}C in both 2Cr-3Mo and 5Cr-5Mo steels. The apparent discrepancy between theoretical and experimental observations has been correlated to kinetic factors.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Copper-nickel electroplating of 3D-printed acrylonitrile butadiene styrene for interference and radiation shielding applications

Here, in this study, electromagnetic and radiation shielding structures were fabricated by 3D printing acrylonitrile butadiene styrene (ABS) structures via fused filament fabrication and electroplating with copper (Cu) and nickel (Ni) metals. Prior to electroplating, the printed ABS materials were made conductive by surface electrodeposition of polypyrrole (PPy). ABS adsorbs the pyrrole monomer, which subsequently polymerizes via oxidation forming conductive PPy layer on the printed structures. The successful anchoring of PPy layer can be attributed to its hydrogen bonding and electrostatic interactions with ABS. Thermal analysis, optical, and electron microscopy equipped with energy dispersive X-ray were employed to characterize the printed shielding structures, while the interference and radiation shielding effectiveness were evaluated using a spectrum analyzer and dosimeter, respectively. The interference shielding was found to be effective at 60 ± 5 dB over relatively small frequency range. Shielding was also apparent against gamma and X-ray ionizing rays, but more significantly effective against beta rays. Furthermore, the Cu/Ni coating was able to reduce any heat-induced dimensional changes for the 3D printed ABS substrate without compromising the mechanical integrity.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2017

Neutron interferometry detection of early crack formation caused by bending fatigue in additively manufactured SS316 dogbones

In our research, fatigue in selective laser melted (SLM) and conventionally manufactured stainless steel (SS) 316 dogbones was studied with neutron imaging methods for attenuation, diffraction, and scattering. Neutron attenuation tomography and Bragg edge imaging did not reveal crack formation. Conversely, to efficiently detect the microcrack evolution, two methods of grating-based neutron interferometry, Talbot-Lau and far-field, were employed. Both interferometry methods detect early crack formation via the dark-field (scattering) images, especially for porous microstructures in the range of 0.6 μm to 2 μm. The dark-field image combines sensitivity to micrometer-sized scattering centers at crack formation with sub-millimeter imaging resolution. The crack formation observed with neutron interferometry dark-field was validated post-imaging with additional fatigue cycles to fracture. Further inspection was performed by scanning electron microscopy (SEM) and optical photography. In the two fatigued dogbones, SLM and conventional crack formation was determined to within 1 mm.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2014

Conversion of Nuclear Waste into Nuclear Waste Glass: Experimental Investigation and Mathematical Modeling

The melter feed, slurry, or calcine charged on the top of a pool of molten glass forms a floating layer of reacting material called the cold cap. Between the cold-cap top, which is covered with boiling slurry, and its bottom, where bubbles separate it from molten glass, the temperature changes by up to 1000 K. The processes that occur over this temperature interval within the cold cap include liberation of gases, conduction and consumption of heat, dissolution of quartz particles, formation and dissolution of intermediate crystalline phases, and generation of foam and gas cavities. These processes have been investigated using thermal analyses, optical and electronic microscopies, x-ray diffraction, as well as other techniques. Properties of the reacting feed, such as heat conductivity and density, were measured as functions of temperature. Investigating the structure of quenched cold caps produced in a laboratory-scale melter complemented the crucible studies. The cold cap consists of two main layers. The top layer contains solid particles dissolving in the glass-forming melt and open pores through which gases are escaping. The bottom layer contains bubbly melt or foam where bubbles coalesce into larger cavities that move sideways and release the gas to the atmosphere. The feed-to-glass conversion became sufficiently understood for representing the cold-cap processes via mathematical models. These models, which comprise heat transfer, mass transfer, and reaction kinetics models, have been developed with the final goal to relate feed parameters to the rate of glass melting.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2019

Nature of Moisture-Induced fogging defects in scintillator plastic

Polyvinyl toluene (PVT) scintillator plastic may degrade in the field due to inward water diffusion at elevated temperatures, which exceeds the saturation limit at lower temperatures, and after long periods of time (e.g., many years), leads to the formation of disk-like defects that attenuate scintillation light, leading to detector degradation. In this work, using fractography and high-magnification optical and electron microscopy to characterize the water-induced defects, a model of the fogging process is hypothesized as follows: excess water present at low temperatures diffuses to spheroids to minimize contact with the hydrophobic polymer. Through the hydrophobic effect, the entropy of water increases by forming nanoclusters which minimizes the contact between the water and the PVT. As the water nanoclusters grow, they break and fold the polymer into densely-packed crystalline regions creating more space for water within the spheroids. The polymer outside the spheroid resists the shrinkage which builds up tension within the spheroid. Once the tensile stress exceeds the yield strength of the plastic, the spheroid is torn in half resulting in a defect. Excess water then drains into the cavities along the disk thereby further increasing its entropy. Slower cooling (over 1 day) leads to larger spheroids and hence, larger “permanent” defects. Freezing causes some defects to further grow due to the expansion of water to ice. These findings imply that the remaining lifetime of scintillator plastic in the field could be predicted using temperature and humidity data thereby mitigating security risks of degraded radiation portal monitors.

36 MATERIALS SCIENCE↗