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At least 1,729 records · Page 96
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Interfacial Microstructural Evolution and Metallurgical Bonding Mechanisms for IN718 Superalloy Joint Produced by Hot Compressive Bonding

The novel metallurgical joining process for bonding IN718 superalloy was investigated by hot compressive bonding (HCB) process under the deformation temperature range of 1000 °C to 1150 °C and true strains ranging from 0 to 0.5 at a strain rate of 0.001 s{sup −1}. The effect of HCB process parameters on the tensile strength was analyzed. Both the as-deformed and the interfacial microstructures were characterized using the optical microscope, electron backscattered diffraction and transmission electron microscope (TEM) analysis. The results of tensile property revealed that the degree of metallurgical bonding is promoted by increasing deformation temperature and strain. The evolution of the interfacial microstructure showed that the migration of interfacial grain boundary (IGB), which is characterized by discontinuous dynamic recrystallization, is the dominant metallurgical bonding mechanism in the early stages of bonding. TEM analysis indicated that the dislocation density is distributed heterogeneously over both sides of IGB, which is the significant reason for the migration of IGB, during the initial stage of HCB process.

36 MATERIALS SCIENCE↗
DOE OSTI2018

The Temperature Effect on the Compressive Behavior of Closed-Cell Aluminum-Alloy Foams

In this research, the mechanical behavior of closed-cell aluminum (Al)-alloy foams was investigated at different temperatures in the range of 25-450 °C. The main mechanical properties of porous Al-alloy foams are affected by the testing temperature, and they decrease with the increase in the temperature during uniaxial compression. From both the constant/serrated character of stress–strain curves and macro/microstructural morphology of deformed cellular structure, it was found that Al foams present a transition temperature from brittle to ductile behavior around 192 °C. Due to the softening of the cellular structure at higher temperatures, linear correlations of the stress amplitude and that of the absorbed energy with the temperature were proposed. Also, it was observed that the presence of inherent defects like micropores in the foam cell walls induced further local stress concentration which weakens the cellular structure’s strength and crack propagation and cell-wall plastic deformation are the dominant collapse mechanisms. Finally, an energy absorption study was performed and an optimum temperature was proposed.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Compressive Deformation Behavior of Open-Cell Cu-Zn-Al Alloy Foam Made Through P/M Route Using Mechanically Alloyed Powder

Cu-Zn-Al foams of varying porosity fractions using mechanical alloyed powder have been made through powder metallurgy route. Here, NH{sub 4} (HCO{sub 3}) was used as a space holder. Mechanically alloyed Cu-Zn-Al is made using a planetary ball mill taking the ratio of Cu/Zn/Al = 70:25:5 (by weight ratio). The ball/powder ratios were varied in the four ranges 10:1, 15:1, 20:1, and 25:1. Green compacts of milled powder and space holder samples were sintered at three stages at three different temperatures 350, 550, and 850 °C for 1 h at each stage. The crystalline size and particle size as a function of ball/powder ratios were examined. The compressive deformation responses of foams are varied with relative density and the ball/powder ratio. The plateau stress and energy absorption of these foams increase with an increase in relative density but decreases with increase in ball/powder ratio, even though crystalline size decreases. This has further been explained on the basis of particle morphology as a function of ball/powder ratio.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Prediction of the Stress–Strain Behavior of Open-Cell Aluminum Foam under Compressive Loading and the Effects of Various RVE Boundary Conditions

The prediction of the mechanical behavior of metallic foams with realistic microstructure and the effects of various boundary conditions on the mechanical behavior is an important and challenging issue in modeling representative volume elements (RVEs). A numerical investigation is conducted to determine the effects of various boundary conditions and cell wall cross sections on the compressive mechanical properties of aluminum foam, including the stiffness, plateau stress and onset strain of densification. The open-cell AA6101-T6 aluminum foam Duocel is used in the analyses in this study. Geometrical characteristics including the cell size, foam relative density, and cross-sectional shape and thickness of the cell walls are extracted from images of the foam. Then, the obtained foam microstructure is analyzed as a 2D model. The ligaments are modeled as shear deformable beams with elastic-plastic material behavior. To prevent interpenetration of the nodes and walls inside the cells with large deformations, self-contact-type frictionless interaction is stipulated between the internal surfaces. Sensitivity analyses are performed using several boundary conditions and cells wall cross-sectional shapes. The predicted results from the finite element analyses are compared with the experimental results. Finally, the most appropriate boundary conditions, leading to more consistent results with the experimental data, are introduced.

36 MATERIALS SCIENCE↗
DOE OSTI2018

High-Temperature Deformation Behavior of Ti-6Al-2Sn-4Zr-2Mo Alloy with Lamellar Microstructure Under Plane-Strain Compression

High-temperature plane-strain compression of a Ti-6Al-2Sn-4Zr-2Mo (Ti-6242) alloy with a lamellar structure was applied by a thermal simulation machine Gleeble 3800 at a temperature of 1223-1370 K and a strain rate of 0.01-10 s{sup −1}. Constitutive relations between the flow stress and strain at different temperatures and strain rates were constructed based on the Arrhenius equation. Processing maps based on the dynamic material model at strains of 0.5, 1.0, and 1.25 were also constructed to analyze the mechanism and instability of high-temperature deformation. Dynamic recrystallization was found to occur at 1223-1313 K and 0.01-0.1 s{sup −1}, with a peak efficiency of power dissipation of 70%. Observations of the microstructure demonstrated that α platelets and dynamic globularization were responsible for dynamic softening in the α + β phase field. Flow instability behaviors occurred at 1263-1343 K/1.78-10 s{sup −1}, 1233-1283 K/0.1-3.16 s{sup −1}, and 1353-1373 K/0.56-1.78 s{sup −1}, and adiabatic shear bands and microcracks were observed in these domains. Thus, for the lamellar Ti-6242 alloy, the recommended hot rolling parameters were 1243-1333 K and 0.01-0.1 s{sup −1}. Electron backscattered diffraction results revealed that the dynamic restoration mechanism in the β phase field was dynamic recovery when the strain rate was as high as 10 s{sup −1}.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Influence of Cell Anisotropy and Relative Density on Compressive Deformation Responses of LM13-Cenosphere Hybrid Foam

This article deals with closed-cell aluminum alloy LM13-cenosphere hybrid foams (ACHFs) with cell anisotropy prepared through stir casing technique. The compressive deformation behavior of hybrid foams in both transverse and longitudinal directions was measured at a strain rate of 0.01/s. The hybrid foam loaded in longitudinal direction (LD) shows higher plastic collapse stress than that in transverse direction (TD). The stress drop ratio is also observed to be higher in the LD. The plastic collapse stress and energy absorption capacity of ACHFs follow the power law relationship with relative density in both the directions. The plateau stress is higher in case of LD and densification strains are marginally higher in case of LD than that in TD.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Compression Molding and Novel Sintering Treatments for Alnico Type-8 Permanent Magnets in Near-Final Shape with Preferred Orientation

We present economic uncertainty in the rare earth (RE) permanent magnet marketplace, as well as in an expanding electric drive vehicle market that favors permanent magnet alternating current synchronous drive motors, motivated renewed research in RE-free permanent magnets like “alnico,” an Al-Ni-Co-Fe alloy. Thus, high-pressure, gas-atomized isotropic type-8H pre-alloyed alnico powder was compression molded with a clean burn-out binder to near-final shape and sintered to density >99% of cast alnico 8 (full density of 7.3 g/cm 3 ). To produce aligned sintered alnico magnets for improved energy product and magnetic remanence, uniaxial stress was attempted to promote controlled grain growth, avoiding directional solidification that provides alignment in alnico 9. Lastly, successful development of solid-state powder processing may enable anisotropically aligned alnico magnets with enhanced energy density to be mass-produced.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Networks of pipelines for gas with nonconstant compressibility factor: stationary states

For the management of gas transportation networks, it is essential to know how the stationary states of the system are determined by the boundary data. The isothermal Euler equations are an accurate pde-model for the gas flow through each pipe. A compressibility factor is used to model the nonlinear relationship between density and pressure that occurs in real gas in contrast to ideal gas. The gas flow through the nodes is governed by algebraic node conditions that require the conservation of mass and the continuity of the pressure. We examine networks that are described by arbitrary finite graphs and show that for suitably chosen boundary data, subsonic stationary states exist and are uniquely determined by the boundary data. Our construction of the stationary states is based upon explicit representations of the stationary states on each single pipe that can easily be evaluated numerically. We also use the monotonicity properties of these states as functions of the boundary data.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2017

Dynamic Uniaxial Compression of HSLA-65 Steel at Elevated Temperatures

Here, the dynamic response of a high-strength, low alloy Grade 65 (HSLA-65) steel, used by the United States Navy for ship hull construction, is investigated under dynamic uniaxial compression at temperatures ranging from room temperature to 1000 °C using a novel elevated temperature split-Hopkinson pressure bar. These experiments are designed to probe the dynamic response of HSLA-65 steel in its single α-ferrite phase, mixed α + γ-austenite phase, and the single γ-austenite phase, as a function of temperature. The investigation is conducted at two different average strain rates—1450 and 2100/s. The experimental results indicate that at test temperatures in the range from room temperature to lower than 600 °C, i.e. prior to the development of the mixed α + γ phase, a net softening in flow strength is observed at all levels of plastic strain with increase in test temperatures. As the test temperatures are increased, the rate of this strain softening with temperature is observed to decrease, and at 600 °C the trend reverses itself resulting in an increase in flow stress at all strains tested. This increase in flow stress is understood be due to dynamic strain aging, where solute atoms play a distinctive role in hindering dislocation motion. At 800 °C, a (sharp) drop in the flow stress, equivalent to one-half of its value at room temperature, is observed. As the test temperature are increased to 900 and 1000 °C, further drop in flow stress are observed at all plastic strain levels. In addition, strain hardening in flow stress is observed at all test temperatures up to 600 °C; beyond 800 °C the rate of strain hardening isobserved to decrease, with strain softening becoming dominant at temperatures of 900 °C and higher. Moreover, comparing the high strain rate stress versus strain data gathered on HSLA 65 in the current investigation with those available in the literature at quasi-static strain rates, strain-rate hardening can be inferred. The flow stress increases from 700 MPa at 8 × 10 -4 /s to 950 MPa at 1450/s and then to 1000 MPa at 2100/s at a strain of 0.1. Finally, optical microscopy is used to understand evolution of microstructure in the posttest samples at the various test temperatures employed in the present study.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Particle Strain Analysis of Epoxy-Based Composites Following Quasi-Static and Dynamic Compression

We investigate localized strains in polymer-based composites subjected to varying strain-rates and strains. Research on composites is often focused on their bulk mechanical behavior. However, many material phenomena are influenced by their microstructure, such as the mixing and reaction mechanisms of constituents in structural energetic materials. Therefore, the response of composites at the mesoscale is of clear interest; especially as insight into the micro-deformation and damage, and interaction effects between the constituents at the local level will better inform our understanding of the bulk composite constitutive behavior. To more fully understand the composite mechanical behavior at the mesoscale, uniaxial compression experiments were conducted on epoxy reinforced with aluminum (20 or 40 vol%) and nickel (0 or 10 vol%) particles. Additionally, the particle size of aluminum was either 5 or 50 μm in diameter. Experiments were carried out at quasi-static and dynamic strain rates. Resulting microstructures were analyzed to measure the degree of particle strain and compared to the global material strains for different degrees of strain-rate, strain, and particle size and volume fraction. The aluminum particle strain increased with global strain and had a strong dependency on strain rate. Introducing stiffer nickel particles resulted in larger aluminum particle strains. The nickel particle strain was minimal (< 3%) and showed no dependency with strain rate. This research gives insight into the interactions of particle reinforced composite constituents and their deformation at the mesoscale which is important for understanding phenomena such as preignition mechanisms in structural energetic materials.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Simulation and Emulation of X-Ray Diffraction from Dynamic Compression Experiments

Many important aspects of the dynamic thermo-mechanical response of materials occur at the mesoscale, i.e. a physical scale of interactions smaller than what can be adequately described by homogenous behaviors, yet larger than the scale of the atomic lattice. Concurrent advancements in computational power, continuum theory, and experimental diagnostics are enabling unprecedented understanding of such interactions. However, we cannot develop a sufficient level of confidence in such mesoscale capability until the constitutive description of the underlying constituents is reliably representative of their actual physical behavior. Therefore, there is a strong need to combine experimental, modeling, and data-science techniques to validate models of the thermomechanical response of individual single crystals. One experimental diagnostic with high potential impact to shock physics and materials science is in-situ x-ray diffraction. This paper is primarily focused on simulation of x-ray diffraction in shock physics, but with an aim toward quantifying parametric uncertainty of simulation models. Here, we develop and demonstrate a data-science and model-driven approach to constrain the parameterization of continuum models of crystal lattice deformation associated with the shock response of crystalline materials. The framework is built around the connection between continuum hydrodynamic simulations of lattice deformation and a new Bragg diffraction simulation code, BarberShop. The dynamic deformation of a crystal lattice is modeled using the DiscoFlux model within an arbitrary Lagrangian-Eulerian hydrodynamic code, FLAG. These detailed continuum simulations of lattice deformation can be computationally slow, thus a statistical model is used to emulate the evolution of lattice deformation fields in time and across the considered model parameter space. Emulated lattice deformation fields can then be generated rapidly for any combination of physics model parameters. In turn, these fields can be fed into BarberShop to realize a rapid prediction of Bragg diffraction patterns associated with particular values of physics model parameters. The framework enables parameterization of the single crystal model to obtain Bragg diffraction patterns that most closely resemble a corresponding measurement. Furthermore, the framework naturally provides sensitivities of the lattice deformation to the physics parameters. We highlight the utility of this framework through the application to a synthetic closed-loop inverse problem leading to the parameterization of a single crystal material model. As a model problem, we consider the dynamic response of the energetic molecular crystal, cyclotrimethylenetrinitramine (or RDX), under dynamic compression induced by simulated flyer plate impact experiments.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Anisotropic deformation of extruded magnesium alloy AZ31 under uniaxial compression: A study with simultaneous in situ synchrotron x-ray imaging and diffraction

In situ synchrotron x-ray imaging and diffraction are used to investigate anisotropic deformation of an extruded magnesium alloy AZ31 under uniaxial compression along two different directions, with the loading axis (LA) either parallel or perpendicular to the extrusion direction (ED), referred to as LA∥ED and LAED, respectively. Multiscale measurements including stress–strain curves (macroscale), x-ray digital image correlation (mesoscale), and diffraction (microscale) are obtained simultaneously. Electron backscatter diffraction is performed on samples collected at various strains to characterize deformation twins. The rapid increase in strain hardening rate for the LA∥ED loading is attributed to marked {101¯2} extension twinning and subsequent homogenization of deformation, while dislocation motion leads to inhomogeneous deformation and a decrease in strain hardening rate.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Slip transmission of high angle grain boundaries in body-centered cubic metals: Micropillar compression of pure Ta single and bi-crystals

In this study, we seek to probe and understand the mechanical behavior of grain boundaries in pure Ta as a model bcc material using micropillar compression experiments. Three high angle grain boundaries are chosen with varying crystal orientations. Multiple bi-crystal pillars are prepared containing a single, nearly vertical grain boundary in the approximate center of the pillar and compared against their single crystalline pillar counterparts. The main phenomenon of interest was slip transmission or strain transfer in the bi-crystals which was considered to occur when slip traces aligned across the grain boundary. This occurred in two of the three bi-crystals.

36 MATERIALS SCIENCE↗
DOE OSTI2020

In Situ Micro-Pillar Compression to Examine Radiation-Induced Hardening Mechanisms of FeCrAl Alloys

Here, the effects of 5 MeV Fe 2+ ion irradiation at 300°C on the microstructure evolution and deformation behavior of a FeCrAl C26M alloy are presented. It has been found that dislocation loop density increases an order of magnitude from 1 dpa to 16 dpa irradiations, whereas, the dislocation loop size saturates with increasing damage. Micropillars, 600 nm in diameter and 1.3 µm in height, were fabricated and compressed inside grains with <001>, <011> and <111> crystallographic orientations, respectively. {112} <111> has been identified as the primary slip system in both unirradiated and irradiated alloy. The increase in yield stress after irradiation is observed with measurable variation along <001> and <011> vs. along <111>. By applying the Orowan dispersed barrier model, the increase of yield stress is found mainly due to the slip resistance of radiation generated defect loops. Detailed transmission electron microscopy (TEM) studies were performed to quantify the Burgers vector and the distribution of irradiation induced dislocations at elevated strains. It is revealed that localized shear instability is caused by avalanche slip events of ½<111> dislocations gliding out of tested pillars. Simultaneously, a large number of sessile/immobile <100> dislocations formed in the vicinity of slip band, leading to the hardening at elevated strains.

36 MATERIALS SCIENCE↗
DOE OSTI2026

In-Situ Visualization of a Growing Brittle Crack in Aluminum Oxynitride Using Synchrotron X-Rays and the Double-Cleavage Drilled Compression Geometry

Brittle fracture is difficult to study in situ due to the speed of a growing crack and the often-catastrophic nature of failure in brittle materials. As a result, the influence of microstructural considerations, such as orientation, grain boundary locations, and strain field, on the crack path remains poorly understood. Presented in this study is a method addressing this knowledge gap, which utilizes the double-cleavage drilled compression geometry to achieve quasi-stable fracture in aluminum oxynitride (AlON). Synchrotron X-ray micro-computed tomography is used to characterize the crack shape and length, while high-energy diffraction microscopy provides information on the strains, orientations, and shapes of grains in the microstructure surrounding the crack tip. During testing, the crack grew in discrete and irregular jumps while the fracture toughness falls within reported ranges. The crack in AlON is found to have no greater tendency to crack intergranularly as compared to transgranularly, and grains which are cracked transgranularly do not display a trend in orientation or stress when compared to those around which the crack followed a grain boundary. The high resolution of the crack path and microstructural data provides a path forward for modeling and understanding 3D brittle fracture.

Gorske, Sara F.↗
DOE OSTI2021

Asynchronous distributed-memory task-parallel algorithm for compressible flows on unstructured 3D Eulerian grids

Here, we discuss the implementation of a finite element method, used to numerically solve the Euler equations of compressible flows, using an asynchronous runtime system (RTS). The algorithm is implemented for distributed-memory machines, using stationary unstructured 3D meshes, combining data-, and task-parallelism on top of the Charm++ RTS. Charm++’s execution model is asynchronous by default, allowing arbitrary overlap of computation and communication. Task-parallelism allows scheduling parts of an algorithm independently of, or dependent on, each other. Built-in automatic load balancing enables continuous redistribution of computational load by migration of work units based on real-time CPU load measurement. The RTS also features automatic checkpointing, fault tolerance, resilience against hardware failure, and supports power-, and energy-aware computation. We demonstrate scalability up to 25 x 10 9 cells at $\mathscr{O}$10 4 compute cores and the benefits of automatic load balancing for irregular workloads. The full source code with documentation is available at https://quinoacomputing.org.

42 ENGINEERING↗
DOE OSTI2017

Thermally Stratified Compression Ignition: A new advanced low temperature combustion mode with load flexibility

We introduce a new advanced combustion mode, called Thermally Stratified Compression Ignition (TSCI), which uses direct water injection to control both the average temperature and the temperature distribution prior to ignition, thereby providing cycle-to-cycle control over the start and rate of heat release in Low Temperature Combustion (LTC). Experiments were conducted to fundamentally understand the effects of water injection on heat release in LTC. Our results show that water injection retards the start of combustion due to the latent heat of vaporization of the injected water. Furthermore, for start of water injection timings between 20 and 70 degrees before top dead center, combustion is significantly elongated compared to without water injection. The 10–90% burn duration with 6.6 and 9.0 mg of water per cycle was 77% and 146% longer than without water injection, respectively. Forced thermal stratification result from a direct water injection which reduces the heat release rate by local evaporative cooling. Finally, the load limits with and without water injection were determined experimentally. Without water injection, the load range was 2.3–3.6 bar gross IMEP. By using water injection to control heat release, the load range in TSCI was 2.3–8.4 bar gross IMEP, which is a range expansion of over 350%. These results demonstrate that direct water injection can provide significant improvements to both controllability and the range of operability of LTC, thereby resolving the major challenges associated with HCCI.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2024

Heating performance of a vapor compression heat pump cascaded with a thermoelectric heat pump

Air source heat pumps (ASHPs) are widely utilized for heating and cooling in residential buildings; however, their effectiveness in heating mode is compromised during extreme weather conditions. Extensive research endeavors have been undertaken to develop, test, and assess a cost-effective vapor compression ASHP suitable for cold climate regions. Further, this study takes an innovative approach by developing component and system prototypes for a cold climate heat pump. This design combines a thermoelectric heat pump (TEHP) with a traditional residential split ASHP to augment heating capacity in low ambient temperature conditions. The component and system prototypes underwent experimental testing in the psychrometric chambers. The experimental findings revealed a 13.6% to 13.7% increase in total heat pump heating capacity, accompanied by a 3.1% to 5.0% decrease in the coefficient of performance (COP) at ambient temperatures of -15°C and -19°C, when compared to the original ASHP. The COP of the TEHP is relatively constant, ranging from 1.63 to 1.76. This prototype offers a solution to address the challenges associated with reduced heat pump capacity at low ambient temperatures. The experimental results indicated that the lower the ambient temperature, thermoelectric heat pump auxiliary heating can increase the heating efficiency 60% in comparison to electric resistance.

42 ENGINEERING↗