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At least 1,621 records · Page 90
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Microstructure and texture evolution of duplex stainless steels with different molybdenum contents

Highlights: • The 3.05Mo steel has higher resistance to strain-induced transformation than the 0.28Mo steel. • The increased Mo content affects the grain growth of austenite and ferrite due to the effects of segregation and anchoring. • At high annealing temperatures, this Mo retarding effect is weakened. • The suppression of γ-fiber development in the ferrite texture is associated with the increased Mo content. • High amounts of Mo generate unfavorable conditions for the formation of CSL boundaries. - Abstract: The microstructure and texture evolution of duplex stainless steels with different molybdenum contents were studied. For this purpose, hot-rolled 2205 and 2304 samples were solution-annealed at 1100 °C for 1800 s and then cold-rolled to a 75% thickness reduction. This was followed by an isothermal annealing at 900 and 1100 °C for 180 s. The EBSD technique was used to determine the phase ratio, crystallographic texture, and microstructural characteristics. The hot-rolled steel had a work hardened microstructure and the samples submitted to intermediate annealing presented mainly deformation-free grains. Cold rolling resulted in a substantial reduction in the phase spacing with the formation of the strain-induced α′-martensite (SIM) from the metastable austenite. After annealing at 900 °C, the ferrite grains retained the elongated shape of the cold-rolled condition and the primary recrystallization progressed in the austenite phase. Increasing the Mo content increased the resistance to strain-induced martensitic transformation and inhibited the grain growth of austenite phase during annealing at 900 °C. Increasing annealing temperature to 1100 °C promoted the coarsening of both bcc and fcc structures with the formation of annealing twins in the austenitic grains. The recrystallization kinetics and subsequent grain growth occur earlier in ferrite than in austenite phase. Differences in Mo content did not significantly alter the evolution of austenite texture, whereas in the ferrite phase the increase in Mo content suppressed the γ-fiber development. Oriented nucleation was the predominant mechanism observed during the recrystallization of ferritic grains in the 2205 samples. The development of ∑19a boundaries was associated with the selected growth of {554}<225>{sub α} grains in the annealed 2304 samples. Annealing twins were associated with the formation of Σ3 boundaries after the heat treatments. Grain coarsening resulted in a larger fraction of the special boundaries in ferrite phase but inhibited the CSL formation in the austenite phase.

36 MATERIALS SCIENCE↗
NASA NTRS1933

The Effects of Slots and Flaps on Lateral Control of a Low-wing Monoplane as Determined in Flight

This paper presents the results of flight tests made to determine the effect of slots and flaps on the lateral control of a low-wing monoplane. Maximum angular accelerations in roll and yaw produced by sudden application of the ailerons and maximum accelerations in yaw produced by sudden application of the rudder during gliding flight were recorded for the following wing arrangements: (a) no auxiliary device; (b) full-span slots; (c) plain flaps; (d) flaps and full-span slots; (e) wing-tip slots. Rolling- and yawing-moment coefficients were derived from the accelerations. The full span slots and the flaps each had about the same influence on the aileron rolling moments. At values of the lift coefficient obtainable with the plain wing, the effect of these devices was negligible. At the higher lift coefficients obtainable with these devices, the rolling-moment coefficients increased slightly but, despite this increase, the aileron effectiveness progressively decreased with increasing lift coefficient, owing to the corresponding reduction in air speed. In the range covered by the tests, the effectiveness of the controls was appreciably reduced by the wing-tip slots. The adverse yawing moment of the ailerons experienced at the large lift coefficients obtained with the flaps was appreciably less than at similar lift coefficients obtained with either full-span or wing-tip slots. The yawing moments produced by the rudder were only slightly affected by the use of the auxiliary devices. The airplane was found to be laterally unstable with all combinations tested. Because of the angular velocities acquired in the time taken to deflect the ailerons the rolling moments recorded in flight were only about two thirds the values that would have been obtained with the wing restrained as in wind-tunnel tests.

WING SLOTS↗
DOE OSTI2019

Hardening of A6111-T4 Aluminum Alloy at Large Strains and Its Effect on Sheet Forming Operations

In a number of sheet metal stamping and joining processes, the material undergoes large plastic deformation exceeding the range of plastic strain achievable in a standard tensile test prior to material plastic instability. In order to extend the range of effective strains, the multistep rolling process was employed which enabled prestraining of aluminum sheet above 2.0 of true strain. Tensile testing of rolled samples was used to identify the flow stress corresponding to the level of prestrain: By varying the prestrain level, several data points were obtained for the studied flow curve. The numerical simulation using Abaqus software for the cold rolling process of aluminum strips confirmed that majority of the strip is deformed in plane strain compression condition. Performed simulation of the LDH test determined that earlier fracture might occur if the curve obtained via rolling–tensile testing approach is used versus traditional power law approximation and Voce law approximation. The results of simulation for the multistep drawing of a cylindrical cup revealed possible wrinkling in the die entry area during redrawing stage of the process if the rolling–tensile testing flow curve is employed.

36 MATERIALS SCIENCE↗
DOE OSTI2019

AZ61 and AZ61-La Alloys as Anodes for Mg-Air Battery

AZ61 and AZ61-0.5La (wt.%) alloys are prepared by the conventional casting method and then, AZ61 and AZ61-0.5La alloy sheets are obtained with multi-pass hot rolling. Microstructures and electrochemical properties of four alloys are investigated, and discharge properties are tested by an assembled Mg-air battery using alloy anode sheets with a dimension of 70 × 100 × 2.5 mm. Results show that Al{sub 11}La{sub 3} phases are formed in as-cast AZ61-0.5La alloy and promote the grain refinement and the formation of uniform microstructure in as-rolled AZ61-0.5La alloy. As-rolled AZ61-0.5La alloy exhibits a weak self-corrosion tendency but a strong discharge activity. After discharge test for 5 h, the Mg-air battery based on the as-rolled AZ61-0.5La sheet can provide the maximum power output of 1.625 W, and as-rolled AZ61-0.5La anode can supply the maximum energy density of 1417 mWhg{sup −1}. In addition, the relationship between microstructures and discharge properties is sufficiently described and discussed in this paper.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Deformation Strengthening of Uranium and Dilute Uranium Alloys

The strength and ductility of uranium and dilute uranium alloys can be substantially improved by deformation strengthening. The yield strength of unalloyed uranium can be nearly doubled by rolling in the vicinity of 250°C. The embrittling effect of hydrogen is also overcome, eliminating the need for vacuum outgassing to obtain good ductility. Significant differences in longitudinal versus transverse tensile properties result, in part, from texture introduced by unidirectional rolling. Warm rolling of U-2.3%Nb results in both traditional strain hardening and a significant Bauschinger effect, resulting in differences between tensile and compressive yield strength. A similar combination of strain hardening and Bauschinger effect also occurs in deformation strengthened U-0.75%Ti. Warm rolling of U-0.75%Ti results in significantly better combinations of tensile yield strength and ductility than can be obtained by conventional age hardening. Warm rolling prior to aging also reduces the loss of ductility which typically accompanies conventional age hardening. Here, an approach is developed in which the effects of prior deformation on tensile and compressive yield strengths are analyzed in terms of texture, long-range dislocation, and Bauschinger effects. The Bauschinger effect is shown to vary in sign with the type of deformation, thus providing opportunities to tailor tensile and compressive properties.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

Reconfigurable Vanadium Dioxide Nanomembranes and Microtubes with Controllable Phase Transition Temperatures

Here, two additional structural forms, free-standing nanomembranes and microtubes, are reported and added to the vanadium dioxide (VO 2 ) material family. Free-standing VO 2 nanomembranes were fabricated by precisely thinning as-grown VO 2 thin films and etching away the sacrificial layer underneath. VO 2 microtubes with a range of controllable diameters were rolled-up from the VO 2 nanomembranes. When a VO 2 nanomembrane is rolled-up into a microtubular structure, a significant compressive strain is generated and accommodated therein, which decreases the phase transition temperature of the VO 2 material. The magnitude of the compressive strain is determined by the curvature of the VO 2 microtube, which can be rationally and accurately designed by controlling the tube diameter during the rolling-up fabrication process. The VO 2 microtube rolling-up process presents a novel way to controllably tune the phase transition temperature of VO 2 materials over a wide range toward practical applications. Furthermore, the rolling-up process is reversible. A VO 2 microtube can be transformed back into a nanomembrane by introducing an external strain. Because of its tunable phase transition temperature and reversible shape transformation, the VO 2 nanomembrane-microtube structure is promising for device applications. As an example application, a tubular microactuator device with low driving energy but large displacement is demonstrated at various triggering temperatures.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2014

Hot roller embossing system equipped with a temperature margin-based controller

A temperature control system was proposed for hot roller embossing. The roll surface was heated using induction coils and cooled with a circulating chilled water system. The temperature of the roll surface was precisely controlled by a temperature margin-based control algorithm that we developed. Implementation of the control system reduced deviations in the roll surface temperature to less than ±2 °C. The tight temperature control and the ability to rapidly increase and decrease the roll temperature will allow optimum operating parameters to be developed quickly. The temperature margin-based controller could also be used to optimize the time course of electrical power and shorten the cooling time by choosing an appropriate temperature margin, possibly for limited power consumption. The chiller-equipped heating roll with the proposed control algorithm is expected to decrease the time needed to determine the optimal embossing process.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2014

Just enough inflation: power spectrum modifications at large scales

We show that models of 'just enough' inflation, where the slow-roll evolution lasted only 50- 60 e-foldings, feature modifications of the CMB power spectrum at large angular scales. We perform a systematic analytic analysis in the limit of a sudden transition between any possible non-slow-roll background evolution and the final stage of slow-roll inflation. We find a high degree of universality since most common backgrounds like fast-roll evolution, matter or radiation-dominance give rise to a power loss at large angular scales and a peak together with an oscillatory behaviour at scales around the value of the Hubble parameter at the beginning of slow-roll inflation. Depending on the value of the equation of state parameter, different pre-inflationary epochs lead instead to an enhancement of power at low ℓ, and so seem disfavoured by recent observational hints for a lack of CMB power at ℓ∼< 40. We also comment on the importance of initial conditions and the possibility to have multiple pre-inflationary stages.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2016

Constraints on single-field inflation

Many alternatives to canonical slow-roll inflation have been proposed over the years, one of the main motivations being to have a model, capable of generating observable values of non-Gaussianity. In this work, we (re-)explore the physical implications of a great majority of such models within a single, effective field theory framework (including novel models with large non-Gaussianity discussed for the first time below). The constraints we apply — both theoretical and experimental — are found to be rather robust, determined to a great extent by just three parameters: the coefficients of the quadratic EFT operators (δN){sup 2} and δNδE, and the slow-roll parameter ε. This allows to significantly limit the majority of single-field alternatives to canonical slow-roll inflation. While the existing data still leaves some room for most of the considered models, the situation would change dramatically if the current upper limit on the tensor-to-scalar ratio decreased down to r<10{sup −2}. Apart from inflationary models driven by plateau-like potentials, the single-field model that would have a chance of surviving this bound is the recently proposed slow-roll inflation with weakly-broken galileon symmetry. In contrast to canonical slow-roll inflation, the latter model can support r<10{sup −2} even if driven by a convex potential, as well as generate observable values for the amplitude of non-Gaussianity.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2026

Engineering Microstructure in Dry-Processed Cathodes Via Calendering

Calendering serves as a multifunctional step in dry electrode processing that not only densifies the electrode but also induces polytetrafluoroethylene (PTFE) fibrillation and reorganizes the microstructure. These coupled effects are essential for achieving electrical connectivity and sufficient cohesion, yet they also introduce trade-offs, such as active material particle fracture, pore collapse, and excessive porosity loss, that can hinder ionic transport. This research systematically maps the calendering parameter space for LiNi0.6Mn0.2Co0.2O2 (NMC622) dry cathodes with a target thickness of ∼100 µm and porosity of ∼30% by varying roll gaps, roll temperature, roll speed, and the number of passes. A practical processing window for this formulation and electrode architecture is identified that achieves sufficient PTFE fibrillation and strong interfacial contact while minimizing particle fracture and preserving the porosity required for efficient ionic transport. In particular, gradual-gap calendering with moderate per-pass compression mitigates fracture and pore collapse while still reaching the target thickness with reasonable throughput, and slower roll speeds with modest roll temperatures further reduce mechanical damage. These results provide actionable guidance for scaling NMC622-based thick dry-processed cathodes.

Park, Hyunji↗
DOE OSTI2014

SU-E-T-170: Evaluation of Rotational Errors in Proton Therapy Planning of Lung Cancer

Purpose: To investigate the impact of rotational (roll, yaw, and pitch) errors in proton therapy planning of lung cancer. Methods: A lung cancer case treated at our center was used in this retrospective study. The original plan was generated using two proton fields (posterior-anterior and left-lateral) with XiO treatment planning system (TPS) and delivered using uniform scanning proton therapy system. First, the computed tomography (CT) set of original lung treatment plan was re-sampled for rotational (roll, yaw, and pitch) angles ranged from −5° to +5°, with an increment of 2.5°. Second, 12 new proton plans were generated in XiO using the 12 re-sampled CT datasets. The same beam conditions, isocenter, and devices were used in new treatment plans as in the original plan. All 12 new proton plans were compared with original plan for planning target volume (PTV) coverage and maximum dose to spinal cord (cord Dmax). Results: PTV coverage was reduced in all 12 new proton plans when compared to that of original plan. Specifically, PTV coverage was reduced by 0.03% to 1.22% for roll, by 0.05% to 1.14% for yaw, and by 0.10% to 3.22% for pitch errors. In comparison to original plan, the cord Dmax in new proton plans was reduced by 8.21% to 25.81% for +2.5° to +5° pitch, by 5.28% to 20.71% for +2.5° to +5° yaw, and by 5.28% to 14.47% for −2.5° to −5° roll. In contrast, cord Dmax was increased by 3.80% to 3.86% for −2.5° to −5° pitch, by 0.63% to 3.25% for −2.5° to −5° yaw, and by 3.75% to 4.54% for +2.5° to +5° roll. Conclusion: PTV coverage was reduced by up to 3.22% for rotational error of 5°. The cord Dmax could increase or decrease depending on the direction of rotational error, beam angles, and the location of lung tumor.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2014

SU-E-T-463: Quantification of Rotational Variation in Mouse Setup for IGRT

Purpose: New small-animal irradiators include extremely precise IGRT capabilities. However, mouse immobilization and localization remains a challenge. In particular, unlike week-to-week translational displacements, rotational changes in positioning are not easily corrected for in subject setup. Using two methods of setup, we aim to quantify week-to-week rotational variation in mice for the purpose of IGRT planning in small animal studies. Methods: Ten mice were imaged weekly using breath-hold CBCT (X-RAD 225 Cx), with the mouse positioned in a half-pipe support, providing 40 scans. A second group of two mice were positioned in a 3D printed immobilization device, which was created using a CT from a similarly shaped mouse, providing 10 scans. For each mouse, the first image was taken to be the reference image. Subsequent CT images were then rigidly registered, based on bony anatomy. Rotations in the axial (roll), sagittal (pitch), and coronal (yaw) planes were recorded and used to quantify variation in angular setup. Results: For the mice imaged in the half pipe, average magnitude of roll was found to be 5.4±4.6° (range: −12.9:18.86°), of pitch 1.6±1.3° (range: −1.4:4.7°), and of yaw 1.9±1.5° (range −5.4:1.1°). For the mice imaged in the printed setup; average magnitude of roll was found to be 0.64±0.6° (range: −2.1:1.0°), of pitch 0.6±0.4° (range: 0.0:1.3°), and of yaw 0.2±0.1° (range: 0.0:0.4°). The printed setup provided reduction in roll, pitch, and yaw by 88, 62, and 90 percent, respectively. Conclusion: For the typical setup routine, roll in mouse position is the dominant source of rotational variation. However, when a printed device was used, drastic improvements in mouse immobilization were seen. This work provides a promising foundation for mouse immobilization, required for full scale small animal IGRT. Currently, we are making improvements to allo±w the use of a similar system for MR, PET, and bioluminescence.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2015

SU-E-J-46: Evaluation of the Accuracy of a Six Degree of Freedom Robotic Couch Using ConeBeam CT Images of the Isocal Phantom

Purpose The accuracy of Varian PerfectPitch six degree of freedom (DOF) robotic couch was examined using Varian Isocal phantom and cone-beam CT (CBCT) system. Methods CBCT images of the Isocal phantom were taken at different pitch and roll angles. The pitch and roll angles were varied from 357 to 3 degrees in one degree increments by input from service console, generating a total of 49 combinations with couch angle (yaw) zero. The center positions of the 16 tungsten carbide BBs contained in the Isocal were determined with in-house image processing software. Expected BBs positions at different rotation angles were determined mathematically by applying a combined translation/rotation operator to BB positions at zero pitch and roll values. A least square method was used to minimize the difference between the expected BB positions and their measured positions. In this way rotation angles were obtained and compared with input values from the console. Results A total of 49 CBCT images with voxel sizes 0.51 mm × 0.51 mm × 1 mm were used in analysis. Among the 49 calculations, the maximum rotation angle differences were 0.1 degree, 0.15 degree, and 0.09 degree, for pitch, roll, and couch rotation, respectively. The mean ± standard-deviation angle differences were 0.028±0.001 degree, −0.043±0.003 degree, and −0.009±0.001 degree, for pitch, roll, and couch rotation, respectively. The maximum isocenter shifts were 0.3 mm, 0.5 mm, 0.4 mm in x, y, z direction respectively following IEC6127 convention. The mean isocenter shifts were 0.07±0.02 mm, −0.05±0.06 mm, and −0.12±0.02 mm in x, y and z directions. Conclusion The accuracy of the Varian PerfectPitch six DOF couch was studied with CBCTs of the Isocal phantom. The rotational errors were less than 0.15 degree and isocenter shifts were less than 0.5 mm in any direction. This accuracy is sufficient for stereotactic radiotherapy clinical applications.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2017

Structural Transformations in Nematic Liquid Crystals with a Hybrid Orientation

The structural transformations in a nematic liquid crystal (NLC) layer with a hybrid orientation (planar director orientation is created on one substrate and homeotropic director orientation is created on the other) are studied. In the case of a dc voltage applied to the NLC layer, the primary instability is flexoelectric. It causes the appearance of flexoelectric domains oriented along the director on the substrate with a planar orientation. When the voltage increases further, an electroconvective instability in the form of rolls moving almost normal to flexoelectric domains develops along with these domains. Thus, the following spatially periodic structures of different natures coexist in one system: equilibrium static flexoelectric deformation of a director and dissipative moving oblique electroconvection rolls. The primary instability in the case of an ac voltage is represented by electroconvection, which leads to moving oblique or normal rolls depending on the electric field frequency. Above the electroconvection threshold, a transition to moving “abnormal” rolls is detected. The wavevector of the rolls coincides with the initial director orientation on the substrate with a planar orientation, and the projection of the director at the midplane of the NLC layer on the layer plane makes a certain angle with the wavevector. The results of numerical calculations of the threshold characteristics of the primary instabilities agree well with the obtained experimental data.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2020

Characterization Report for the MP-1 Experiment Fabrication Campaign

This report covers the results of MP 1 fuel characterization analysis to provide a detailed understanding of the as-fabricated fuel that would be irradiated in the MP 1 (Mini-Plate 1) experiment. The work was performed at Pacific Northwest National Laboratory (PNNL), Idaho National Laboratory (INL), and Los Alamos National Laboratory (LANL). Characterization of the as-fabricated fuel was performed in accordance with Characterization Plan for the Fabrication of U 10Mo for the MP 1 Experiment, hereinafter the MP 1 Characterization Plan (MAQP 2016). Under the MP 1 Characterization Plan, fuel foils at different points in the foil fabrication process (e.g., hot rolled annealed, cold rolled annealed) were studied to understand the effect of various thermomechanical processes on the fuel microstructure. Samples were sent to each of the three organizations so that testing and analysis could be performed independently using similar equipment and a standardized set of measurement and analysis procedures. The MP 1 experiment will provide an opportunity to understand the effects of processing conditions on the final fuel microstructure, to compare independently obtained results, and achieve a three-way validation. PNNL characterized 28 uranium–10 wt% molybdenum (U 10Mo) samples. Six pieces/specimens from each sample/foil were sectioned, in accordance with the MP 1 Characterization Plan. Similarly, INL and LANL also examined 24 and 17 U 10Mo specimens, respectively. These total 69 samples consist of six types of MP 1 characterization foils fabricated by Babcock and Wilcox Technologies (BWXT) from ingots produced by the Y-12 National Security Complex: • 0.047 in.-thick hot-rolled and annealed samples with and without Zr layers • 0.02 in.-thick cold-rolled and annealed samples with and without Zr layers • 0.01 in.-thick cold-rolled and annealed samples with and without Zr layers. Microstructure, chemical composition, carbide morphology, U 10Mo foil thickness, Zr thickness, mechanical properties (microhardness), and density were evaluated in both longitudinal and transverse directions for foils of the three different thicknesses.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2019

Combining Fluorescence and Phosphorescence to Achieve Very Long Lifetime and Efficient White OLEDs (Final Technical Report)

The objective of our project was to develop a high efficiency, long lived WOLED using a hybrid approach to harvesting singlet and triplet excitons, as described above. WE met out GONOGO metric at the end of year one, achieving an efficiency of nearly 50 lm/W for high quality white light emission. We faced an unforeseen problem in achieving this high efficiency level at high brightness. Our hybrid devices showed a significant roll off in device efficiency as the current is raised, such that our efficiency dropped to ca. 10 lm/W at 1000 nits. This roll off precluded us form achieving our send year targets with regards to efficiency at high brightness and long device lifetime. We spent the majority of our efforts in year two trying to decrease or eliminate this efficiency roll off, but this roll off prevented us from reaching our end of program target of high efficiency at high brightness with long device lifetime. Toward the end of the sixth quarter of the program we began to investigate a new approach, which involved a tandem WOLED, with a hybrid blue/red OLED stacked on a phosphorescent green OLED. The resultant emission from the stack will be white and the tandem structure relaxes the constraints on the materials, which we believe is key issue in the high roll off in efficiency.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

High-Silicon Steel Strip by Single-Step Shear Deformation Processing

It is well known that Fe-Si alloys with Si content higher than in conventional electrical sheet steels (>3.2% Si) can make a significant impact in improving the efficiency of electrical motors if they are available in sheet/foil (strip) forms at suitable cost. While the magnetic and electrical attributes (e.g., resistivity, core loss) of these high-Si Fe alloys, of relevance to electrical motor core laminations, are known to be exceptional, the alloys have limited workability, making them difficult to produce consistently in sheet/foil (strip) forms. Current processing techniques such as rolling, while adequate for producing conventional electrical steel sheet, do have important disadvantages - large energy consumption and emissions, limitations in processing of low-workability alloys (e.g., high-Si content steels), large-scale plant infrastructure, and less than adequate capability to engineer sheet metals with specific microstructures (e.g., fine-grained) and crystallographic textures (e.g., shear textures). It is therefore of interest to have an alternative commercial process that can produce sheet/foil (strip) from high-Si Fe alloys and which can also overcome some of the deficiencies of current multistage strip processes. The goal of the present project was design and demonstration of a new energy-efficient pilot process for producing high-Si electrical steel strip of commercial widths and thickness, and with superior electrical and magnetic properties than current electrical steels (Fe-3.2% Si as benchmark). The applications domain for these steels is electrical motor core laminations. We have addressed this goal by accomplishment of the following specific objectives and tasks: a) Development of an Fe-4Si-4Cr alloy with electrical resistivity >80 μΩ-cm, induction flux density >1.48 T at 5000 A/m and core loss 35% lower than the benchmark 3.2% Si alloy. The alloy which meets DOE target specifications for motor core attributes was designed with the Si content controlled for the electrical properties and the Cr content tailored to meet material/process workability requirements. b) A unique machining-based deformation processing system was designed and scaled-up to produce strip of commercial width (25 mm to 150 mm) and thickness (up to 0.5 mm) from the Fe-4Si-4Cr alloy and other alloys of varied workability including copper, Al6061-T6 and naval brass. The key attributes of the machining-based strip production are deformation processing by concentrated simple-shear; single-step production of strip from ingot using compact machine infrastructure; strip surface finish of Ra 0.35 to 1 micrometer that is comparable/superior to that of rolled strip; discrete production of strip that can potentially be done at point of use; and controllability of strip mechanical/formability properties by deformation control. c) The electrical, magnetic, surface quality, mechanical, formability, and metallurgical properties/attributes of the machining-based strip were established by direct ASTM standard or equivalent measurement techniques. d) Punching characteristics of the strip in terms of load, edge quality and macro defects were similar to those of conventional 3.2% Si electrical steels. These punching characteristics are critical from a manufacturability perspective for motor/transformer core applications. e) A modeling framework for energy analysis of multistage rolling and the machining-based deformation processing has been established. Application of this modeling to the two strip-processes showed that the machining-based process requires significantly lower specific energy for processing, ~ 25% of that for rolling. The modeling framework can be adapted for a range of sheet-metal forming, bulk metal forming, and machining processes. It can be used to identify key parameters controlling process specific energy. f) A comparative analysis of advantages and disadvantages of machining-based processing against rolling for strip production. The single stage machining-based processing, with compact infrastructure, represents a new manufacturing paradigm for sheet and foil manufacturing that can potentially also be applied to advanced titanium, aluminum, copper and magnesium alloys. The goals and objectives were accomplished by a cross-disciplinary project team comprising of personnel from Purdue University; M4 Sciences LLC, a small-business focused on advanced manufacturing technology development; the Pacific Northwest National Labs; and tool manufacturers. The team is currently in advanced discussions with multiple entities for future process development for commercialization.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Characterization Report for the MP-1 Experiment Fabrication Campaign (Rev.1)

This report covers the results of MP 1 fuel characterization analysis to provide a detailed understanding of the as-fabricated fuel that would be irradiated in the MP 1 (Mini-Plate 1) experiment. The work was performed at Pacific Northwest National Laboratory (PNNL), Idaho National Laboratory (INL), and Los Alamos National Laboratory (LANL). Characterization of the as-fabricated fuel was performed in accordance with Characterization Plan for the Fabrication of U 10Mo for the MP 1 Experiment, hereinafter the MP 1 Characterization Plan (MAQP 2016). Under the MP 1 Characterization Plan, fuel foils at different points in the foil fabrication process (e.g., hot rolled annealed, cold rolled annealed) were studied to understand the effect of various thermomechanical processes on the fuel microstructure. Samples were sent to each of the three organizations so that testing and analysis could be performed independently using similar equipment and a standardized set of measurement and analysis procedures. The MP 1 experiment will provide an opportunity to understand the effects of processing conditions on the final fuel microstructure, to compare independently obtained results, and achieve a three-way validation. PNNL characterized 28 uranium–10 wt% molybdenum (U 10Mo) samples. Six pieces/specimens from each sample/foil were sectioned, in accordance with the MP 1 Characterization Plan. Similarly, INL and LANL also examined 24 and 17 U 10Mo specimens, respectively. These total 69 samples consist of six types of MP 1 characterization foils fabricated by Babcock and Wilcox Technologies (BWXT) from ingots produced by the Y-12 National Security Complex: (a.) 0.047 in.-thick hot-rolled and annealed samples with and without Zr layers; (b.) 0.02 in.-thick cold-rolled and annealed samples with and without Zr layers; and (c.) 0.01 in.-thick cold-rolled and annealed samples with and without Zr layers. Microstructure, chemical composition, carbide morphology, U 10Mo foil thickness, Zr thickness, mechanical properties (microhardness), and density were evaluated in both longitudinal and transverse directions for foils of the three different thicknesses.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗