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At least 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Numerical Investigation of the Effect of Rolling on the Localized Stress and Strain Induction for Wire + Arc Additive Manufactured Structures

Cold rolling can be used in-process or post-process to improve microstructure, mechanical properties and residual stress in directed-energy-deposition techniques, such as the high deposition rate wire + arc additive manufacturing (WAAM) process. Finite element simulations of the rolling process are employed to investigate the effect of rolling parameters, in particular rolling load and roller profile radius on the residual stress field as well as plastic strain distribution for the profiled roller. The results show the response to rolling of commonly used structural metals in WAAM, i.e., AA2319, S335JR steel and Ti-6Al-4V, taking into account the presence of residual stresses. The rolling load leads to changes in the location and the maximum value of the compressive residual stresses, as well as the depth of the compressive residual stresses. However, the roller profile radius only changes the maximum value of these compressive residual stresses. Changing the rolling load influences the equivalent plastic strain close to the top surface of the wall as well as in deeper areas, whereas the influence of the roller profile radius is negligible. The plastic strain distribution is virtually unaffected by the initial residual stresses prior to rolling. Finally, design curves were generated from the simulations for different materials, suggesting ideal rolling load and roller profile combinations for microstructural improvement requiring certain plastic strains at a specific depth of the additive structure.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Design and Application of CSC-Roll for Heavy Reduction of the Bloom Continuous Casting Process

Center quality control is a key issue affecting large-section bloom production and product quality. The central convex roll could avoid the bloom side part and yield a high reduction amount, which benefit the implement of heavy reduction (HR) for bloom continuous casting process without upgrading the mechanical and hydraulic system of withdrawal and straightening machine. In this work, a curving surface convex roll (CSC-Roll), which could significantly improve bloom center quality, was designed by finite element simulation for a 360 mm × 450 mm #45 steel continuous casting bloom. The optimal roll surface shape of the CSC-Roll was determined based on an analysis of the distribution of the reduction amount in the bloom center and the strain of the bloom centerline and inner surface. The calculation results showed that the optimal size of the CSC-Roll was 200 mm in convex platform region length, 30 mm in convex platform region height, and 80 mm in gradient curvature region length. The bloom heat transfer and deformation behavior in the CSC-Roll reduction process were then analyzed. The results showed that in the CSC-Roll HR process, 61.71 pct of the reduction amount could be transmitted to the inner side of the porosity zone. Macrographs of the 360 mm × 450 mm #45 steel continuous casting bloom proved that the bloom center quality was significantly improved after CSC-Roll HR was applied.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Elevated temperature tensile tests on DU–10Mo rolled foils

We report that studies were completed to obtain tensile mechanical properties for uranium-10wt.% molybdenum (U-10Mo) foils which were subjected to four different thermomechanical processing conditions. U-Mo alloy foils are being investigated to support fuel conversion of high power research reactors from their current high enriched fuel form to a low enriched fuel form. Mechanical properties of the fuel foil have an effect on irradiation performance and fuel fabrication and therefore are required to support modeling and qualification of new low-enriched uranium monolithic fuel plate designs. The data contained in this document contributes to fuel qualification by fulfilling the requirement that physical properties related to fuel meat be established. It is expected that depleted uranium-10wt% Mo (DU–10Mo) mechanical behavior is representative of the low-enriched U10-Mo to be used in actual fuel plates; therefore DU–10Mo was studied to simplify material processing, handling, and testing requirements. In this report, the different thermomechanical treatments included variations of wrought hot and cold rolling reduction and post rolling annealing. Each of the four foils was hot rolled. After hot rolling reduction, three of the four foils were further reduced by cold rolling. One of the three was reduced a further 20% by cold rolling, and the remaining two were reduced 50% by cold rolling. Following cold rolling reduction, one of the two foils which had been reduced 50% by cold rolling was annealed at 650?°C. Performing this analysis allows assessment of the impact of foil fabrication history on the resultant tensile properties DU–10Mo fuel foils. Tensile properties of DU–10Mo at room temperature through approximately 400 °C determined from the tests conducted herein suggest the material is stronger and has lower ductility than what has been reported previously in the literature. The explanation for these differences has yet to be determined, but is likely related to differences in grain size and/or impurity content, and variation in fabrication history. At the highest temperatures tested (550 °C) better agreement between the values reported here and available literature was found. As expected, yield and ultimate tensile strength decreased with increasing test temperature. Generally, the yield stress for all foil processing conditions was found to be in the range of 1100 MPa for room temperature tests, and in the range of 200 MPa for tests conducted at 550 °C. Ultimate tensile stress was in the range of 1175 MPa at room temperature, decreasing to approximately 225 MPa at 550 °C. Lastly, elongation increased significantly, from 0 to 2% at room temperature to 50% or more for the tests at 550 °C.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Carbide Particle Redistribution in U-10Mo Alloy during Hot and Cold Rolling Processes: Synthetic Microstructure-Based Finite-Element Approach

The influence of initial carbide particle distribution features on particle fracture and the evolution of stringer distribution within an alloy of uranium with 10 weight percent molybdenum during cold rolling was investigated in this study. This work will provide guidance to casting optimization work and identify actionable process changes to eliminate the surface features directly attributed to carbides. In a previous study, various synthetic microstructure-based finite-element (FE) models were generated with consideration of different parameters (i.e., particle shape, particle volume fraction, and particle distribution), and used to examine the effects of hot rolling on the microstructure evolution. In this study, microstructures after ~80% hot rolling were used as the initial microstructures for the subsequent cold rolling simulation. Plane-strain compression loading was employed in the FE models to simulate cold rolling with reductions from ~80% to ~94%. Stringer analyses with the consideration of particle fracture were then performed with the simulated cold rolling results. The results of void evolution analyses show that microstructures with elliptical particles incorporate a much larger (almost double) void volume fraction than those with circular particles, indicating that the elliptical particles are fractured more easily than the circular ones. The results from the fracture mode analyses show that, under the adopted simple compression loading assumption, almost all the particles (i.e., >99%) were fractured by tensile separation. The results of stringer analyses show that, during cold rolling, the stringer volume fractions increase substantially due to the particle fracture, especially for the microstructures with the elliptical particles, and that the stringer volume fractions from stringers comprising many particles tend to increase faster. The maximum stringer lengths for the microstructures with circular particles tend to remain constant or decrease during cold rolling, whereas those for elliptical particles tend to slightly increase after a slight decrease. The number of particles at the surface increases very rapidly due to particle fracture during cold rolling.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Texture Evolution in an Al-Cu-Mg Alloy During Hot Rolling

The texture evolution in the intermediate (the 1/4 thickness) layer of hot-rolled Al-Cu-Mg alloy sheets was investigated by the x-ray diffraction technique, electron backscattered diffraction analysis and transmission electron microscopy observation. The results showed that a texture transition from the shear texture {001}<110> to the β-fiber textures occurred as the rolling temperature increased to 420 °C. The shear strain caused by friction resulted in this strong shear texture formation at the low rolling temperature. As the rolling temperature increased, the plane strain substituting the shear strain dominated in the intermediate layer, giving rise to a significant increase in the β-fiber textures. Increasing the rolling temperature was found to preferentially activate the non-octahedral {112}<110> slip system, thereby benefiting the development of strong Brass. At the low rolling reduction of 74%, the textures with low intensity tended to converge on the α-fiber, containing Goss, Brass, P and L components. As the rolling reduction increased to 90%, the textures were strengthened and gradually flew toward the β-fiber, containing Brass, Copper and S components. The S and Copper bands were found to be the preferential sites for the development of recrystallizing Cube grains during hot rolling.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Effect of cold rolling on microstructure and mechanical property of extruded Mg–4Sm alloy during aging

Microstructure and mechanical properties of the Mg–4Sm (wt.%) alloy, prepared via combined processes of extrusion, cold rolling and aging, have been investigated. The hot extruded alloy exhibits a weak rare earth magnesium alloy texture with < 11 − 21 >//ED, while the cold-rolled alloy shows a stronger basal texture with < 0001 >//ND. Many tensile twins and double twins are observed in grains after rolling. The cold-rolled alloy shows a weak age-hardening response compared with the extruded alloy, which is the result of more precipitation in the twin boundary during aging. The rolled alloy exhibits almost no precipitate free zone during aging compared with the extruded alloy. The higher proof stress of the rolled alloy in peak-aged condition is attributed to the presence of twin boundaries, stronger basal texture, higher dislocation density, and the suppression of precipitate free zone compared with the extruded alloy. - Highlights: • No precipitate free zone appears in cold-rolled alloy after aging. • Segregation and precipitates are observed in twin boundaries and grain boundaries. • Cold-rolled alloy shows a weak age-hardening response.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Effect of cold rolling on the microstructural evolution of new β-typed Ti–6Mo–6V–5Cr–3Sn–2.5Zr alloys

A Ti–6Mo–6V–5Cr–3Sn–2.5Zr (wt.%) alloy was designed as a new metastable β-Ti alloy. The effect that cold rolling had on the microstructural evolution of the material was investigated via optical microscopy (OM), X-ray diffraction (XRD), electron back-scattered diffraction (EBSD) and transmission electron microscopy (TEM) measurements. A single β phase formed in the alloy after solution treatment at 780 °C for 30 min followed by water quenching. The solution-treated alloy was cold rolled with thickness reductions of 10%, 30%, 50% and 70%, and the hardness values increased as the thickness of the specimen decreased. The textures of the cold rolled specimen were characterized according to the 〈110〉 partial parallel to the rolling direction as the rolling reduction increased. The crystallographic orientation showed principal α-fiber textures for (111)〈110〉 and (112)〈110〉. The cold deformation led to the appearance of martensite α″ phases, particularly stress-induced martensite (SIM) α″ phases. - Highlights: • Effect of cold rolling on new β-typed Ti-6Mo-6V-5Cr-3Sn-2.5Zr alloy was studied. • A single β phase was obtained after solution treatment at 780 °C for 30 min. • α-Fiber textures became dominated with the increase in cold rolling reduction. • A stress-induced α″ martensite was caused by cold rolling.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Influence of differential speed rolling ratio on the ridging behavior of ultra purified 17%Cr ferritic stainless steel

Highlights: • Differential rolling process improves ridging resistance of ferritic stainless steel. • Texture orientation inhomogeneity were attributed to non-uniform deformation. • Shear bands results in homogeneous deformation and recrystallization nucleation. • Uniform recrystallization grains and random orientation grains were obtained. - Abstract: The effect of the differential speed rolling on the ridging resistance and the crystallographic texture evolution of ultra purified 17%Cr ferritic stainless steel was investigated in order to select the optimal procedure for improving the surface quality. In the present study, the three different cold rolling processes were carried out: a conventional cold rolling and two different speed ratios asymmetric rolling. In the conventional cold rolling, the ridging of ferritic stainless steel was pronounced due to the band-like clusters of grains with similar crystallographic orientations. For differential speed rolling, ridging depth decreased and ridging was less pronounced when a higher different speed ratio was applied. The results show that severe ridging is attributed to the presence of band-like clusters of γ-fiber (<111>//ND) oriented grains. The shear bands introduced by differential speed rolling can enhance the nucleation for recrystallization both in grain interiors and grain boundaries, which can fragment the band-like clusters of similar orientation effectively, promoting the random grain orientation and improving surface quality.

36 MATERIALS SCIENCE↗
DOE OSTI2011

Finite element modelling of process-integrated powder coating by radial axial rolling of rings

The process-integrated powder coating by radial axial rolling of rings represents a new hybrid production technique applied in the manufacturing of large ring-shaped work pieces with functional layers. It is thought to break some limitations that come along with the hot isostatic pressing (HIP) which is used nowadays to apply the powdery layer material onto the rolled substrate ring. Within the new process the compaction of the layer material is integrated into the ring rolling and HIP becomes dispensable. Following this approach the rolling of such compound rings brings up some new challenges. The volume of a solid ring stays nearly constant during the rolling. This behaviour can be exploited to determine the infeed of the rollers needed to reach the desired ring shape. Since volume consistency cannot be guaranteed for the rolling of a compound ring the choice of appropriate infeed of the rollers is still an open question. This paper deals with the finite element (FE) simulation of this new process. First, the material model that is used to describe the compaction of the layer material is shortly reviewed. The main focus of the paper is then put on a parameterized FE ring rolling model that incorporates a control system in order to stabilize the process. Also the differences in the behaviour during the rolling stage between a compound and a solid ring will be discussed by means of simulation results.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Validation testing of the Canberra mobile Feed Roll Assay system - 15404

Japanese farmers grow various grasses as feed for cattle. These are rolled up and sealed for future use. Canberra has created a special truck to monitor these Feed Rolls, called 'Feed Roll Assay System [FRAS]'. On the bed of the truck is the shield containing a large NaI detector. The detector is 3x5x16'' in size, the same size as used in the Canberra FastScan Whole Body Counter. The detector is also LED-stabilized, to keep the gain constant under the wide range of temperature variations expected for this outdoor measurement instrument. The Canberra Osprey digital MCA is connected to the detector. The detector and the MCA are housed in a water proof box, which is surrounded on the bottom and all sides by a 15 cm thick steel shield. A portion of the shield at the top is open where the detector can view the Feed Rolls placed there. A single ethernet cable goes to a laptop PC which provides power to the MCA and detector, and also transmits the signal to the PC. The system was calibrated using MCNP for a variety of different densities, and Feed Roll sizes. The Japanese version of the Canberra Genie software is used to analyze the spectra and compute the Bq/kg concentration of the Feed Roll. The shielding is sufficient so that at a 5 uSv/hr background dose rate, no Cs-137 or Cs-134 peaks were detected in a 1 hour count. Measurements were performed in 0.2 uSv/hr dose rate, using uncontaminated Feed Rolls at various counting times. The MDA for Cs-137 was 11.9 Bq/kg at 30 seconds, 8.2 Bq/kg for 60 seconds, and 1.1 Bq/kg at 3600 seconds count time. The relative measurement uncertainty of the FRAS measurements was 9.4 to 13%, as compared to assays of samples extracted [30-45%] and in-situ Ge measurements [6.0 - 7.1%]. The FRAS measurement results have considerably better precision than measurements of samples extracted from the Feed Rolls, and are much faster than the in-situ Ge measurements and have just about the same uncertainty. (authors)

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2018

Effects of Changing Hot Rolling Direction on Microstructure, Texture and Mechanical Properties of Cu-2.7Be Sheets

A hot rolling scheme (cross-rolling and unidirectional rolling) was adopted to process Cu-2.7Be sheets used as multiplier dynodes in photomultiplier. The effects of changing rolling direction on microstructure, texture and mechanical properties were studied by a combination of XRD, EBSD and TEM. It was found that higher copper-type texture and lower brass texture intensity were obtained in the ultimately cross-rolling (CR) sheet compared with the unidirectional rolling (UR) sheet.The EBSD results indicated that the grain orientation from mainly 〈101〉 for UR sample turns to random for CR sample. Great enhancements in YS and UTS after unidirectional rolling were attributed to the massive and polygonal γ precipitates. The CR sample exhibited lower anisotropy, because of the increase of S and γ precipitates with spherical and tiny shape.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Mechanical Properties and Interface Evaluation of Al/AZ31 Multilayer Composites Produced by ARB at Different Rolling Temperatures

Many researchers have studied the microstructure and mechanical properties of Al/Mg composites rolled at a unique temperature; however, the effect of rolling temperature, which is one of the more decisive accumulative roll bonding (ARB) parameters, has not been investigated. In this work, laminated Al/Mg composites were fabricated by ARB at different temperatures using AZ31 magnesium alloy and commercially pure aluminum sheets. The microstructure of the layers and the mechanical properties of the rolled Al/AZ31 composites were investigated. Tensile and bending properties of the multilayer materials were examined by tensile and three-point bending tests. The results showed that mechanical bonding of the layers was improved with increasing rolling temperature. As a result, the intermediate rolling temperature (300 °C) indicated the best mechanical properties. Moreover, hot rolling caused an accelerated formation of intermetallic compounds.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Rolling Deformation on the Microstructure and Mechanical Properties of an Extruded Mg-Zn-Ca Alloy

The microstructure and mechanical properties of an as-extruded Mg-4.5Zn-1.1Ca (wt.%) alloy subjected to unidirectional rolling and cross-rolling were compared in the present study. The results indicated that rolling deformation refined the microstructure, dispersed second phases and modified the texture, which resulted in an improvement in the mechanical properties of the as-rolled alloys compared with those of the as-extruded alloy. The yield strength of the Mg-4.5Zn-1.1Ca (wt.%) alloy increased from 173 to 297 MPa after unidirectional rolling. The initial fragmented Ca{sub 2}Mg{sub 6}Zn{sub 3} phases were further refined after rolling deformation, which clearly restricted the grain growth and gave rise to a fine microstructure. It was also found that rolling deformation intensified the basal texture in comparison with the as-extruded alloy, which was related to particle pinning.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Annealing of (DU-10Mo)-Zr Co-Rolled Foils

Producing uranium-10wt% molybdenum (DU-10Mo) foils to clad with Al first requires initial bonding of the DU-10Mo foil to zirconium (Zr) by hot rolling, followed by cold rolling to final thickness. Rolling often produces wavy (DU-10Mo)-Zr foils that should be flattened before further processing, as any distortions could affect the final alignment and bonding of the Al cladding to the Zr co-rolled surface layer; this bonding is achieved by a hot isostatic pressing (HIP) process. Distortions in the (DU-10Mo)-Zr foil may cause the fuel foil to press against the Al cladding and thus create thinner or thicker areas in the Al cladding layer during the HIP cycle. Post machining is difficult and risky at this stage in the process since there is a chance of hitting the DU-10Mo. Therefore, it is very important to establish a process to flatten and remove any waviness. This study was conducted to determine if a simple annealing treatment could flatten wavy foils. Using the same starting material (i.e. DU-10Mo coupons of the same thickness), five different levels of hot rolling and cold rolling, combined with five different annealing treatments, were performed to determine the effect of these processing variables on flatness, bonding of layers, annealing response, microstructure, and hardness. The same final thickness was reached in all cases. Micrographs, textures, and hardness measurements were obtained for the various processing combinations. Based on these results, it was concluded that annealing at 650°C or higher is an effective treatment to appreciably reduce foil waviness.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2014

Measurement method for roll angular displacement with a high resolution by using diffraction gratings and a heterodyne interferometer

The roll angle measurement is difficult to be achieved directly using a typical commercial interferometer due to its low sensitivity in axial direction, where the axial direction is orthogonal to the plane of the roll angular displacement. A roll angle measurement method combined diffraction gratings with a laser heterodyne interferometer is discussed in this paper. The diffraction grating placed in the plane of a roll angular displacement and the interferometer arranged in the plane's orthogonal direction, constitute the measurement pattern for the roll angle with high resolution. The roll angular displacement, considered as the linear, can be tested precisely when the corresponding angle is very small. Using the proposed method, the angle roll measurement obtains the high resolution of 0.002{sup ″}. Experiment has proved its feasibility and practicability.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2015

Inflation with a constant rate of roll

We consider an inflationary scenario where the rate of inflaton roll defined by {sup ··}φ/H φ-dot remains constant. The rate of roll is small for slow-roll inflation, while a generic rate of roll leads to the interesting case of 'constant-roll' inflation. We find a general exact solution for the inflaton potential required for such inflaton behaviour. In this model, due to non-slow evolution of background, the would-be decaying mode of linear scalar (curvature) perturbations may not be neglected. It can even grow for some values of the model parameter, while the other mode always remains constant. However, this always occurs for unstable solutions which are not attractors for the given potential. The most interesting particular cases of constant-roll inflation remaining viable with the most recent observational data are quadratic hilltop inflation (with cutoff) and natural inflation (with an additional negative cosmological constant). In these cases even-order slow-roll parameters approach non-negligible constants while the odd ones are asymptotically vanishing in the quasi-de Sitter regime.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2016

Large slow roll parameters in single field inflation

We initially consider two simple situations where inflationary slow roll parameters are large and modes no longer freeze out shortly after exiting the horizon, treating both cases analytically. By modes, we refer to the comoving curvature perturbation R. We then consider applications to transient phases where the slow roll parameters can become large, especially in the context of the common 'fast-roll' inflation frequently used as a mechanism to explain the anomalously low scalar power at low l in the CMB. These transient cases we treat numerically. We find when ε, the first slow roll parameter, and only ε is large, modes decay outside the horizon, and when δ, the second slow roll parameter, is large, modes grow outside the horizon. When multiple slow roll parameters are large the behavior in general is more complicated, but we nevertheless show in the 'fast-roll' inflation case, modes grow outside the horizon.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2025

Effects of Grain Size and Interstitial Content on Recrystallization in Nb after Cold Rolling

A fully recrystallized microstructure with a fine grain size can improve the performance of superconducting radio-frequency (SRF) cavities produced from high-purity Nb (ASTM B393–18 Type 5 Nb) while providing mechanical strength. Recrystallization depends on impurity content, initial microstructure, deformation state, and annealing conditions. To better understand how fine-grained, fully recrystallized microstructures may be produced, the recrystallization behaviors of Type 5 and Type 2 Nb materials were studied. Type 5 Nb specimens were produced with both fine and coarse initial grain sizes. All were cold rolled and then annealed under vacuum for one hour to determine the rolling reductions and temperatures required for recrystallization. The recrystallized fraction exceeded 95% in fine-grained Type 5 Nb rolled to a 30% or greater thickness reduction and then annealed at 800 °C or higher. The coarse grained Type 5 Nb required greater rolling reductions to produce any recrystallized grains at 800 °C. The higher interstitial content of the Type 2 Nb required a temperature of 1000 °C or higher to reach a recrystallized fraction greater than 95% in specimens rolled to a 60% reduction. Recrystallization is more easily achieved during annealing at a given temperature for a set time by increasing rolling reduction, decreasing interstitial content, and decreasing initial grain size prior to cold rolling. In conclusion, to avoid grain growth following recrystallization, which increases grain size, the minimum time and temperature necessary for complete recrystallization should be applied.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗