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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 1,747 records · Page 97
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Forced Cooling Friction Stir Welding of 2060-T8 Al-Li Alloy

Friction stir welding of 2060-T8 Al-Li alloy was experimentally investigated. Forced cooling process was realized by placing two copper pressure plates with a waterway on both sides of weld top surface. The relations between joint formation, microstructures and mechanical properties were mainly discussed. Compared with conventional joint by natural cooling, the welding joint with smaller flashes by forced cooling has the smaller well-distributed grains and higher microhardness in the stir zone (SZ). The tensile strength and elongation of forced cooling joint, respectively, reach 445.7 MPa and 6.7%, which are obviously higher than those of the conventional joint. The fracture locations of the conventional and forced cooling joints are located in the SZ, and the fracture surface morphologies show a typical ductile fracture mode.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Electrodeposition and Characterization of Cr-MoS{sub 2} Composite Coatings

In this study, Cr-MoS{sub 2} composite coatings were electrodeposited from conventional Cr{sup +6} baths containing different amounts of MoS{sub 2} particles and various types of surfactant (cationic and anionic). The effect of bath chemical composition on the coatings properties like their microstructure, morphology, chemical composition, corrosion behavior, surface roughness and microhardness was investigated using x-ray diffraction, scanning electron microscopy (SEM), energy-dispersive x-ray analysis, potentiodynamic polarization, electrochemical impedance spectroscopy, surface profilometry and Vickers microhardness measurement techniques, respectively. The results showed that incorporation of MoS{sub 2} particles into the composite coatings is very limited and Cr matrix with very low crystallinity will be electrodeposited at various experimental conditions. The presence of MoS{sub 2} particles in the bath (up to an optimum value) leads to the formation of the composite coatings with lower surface roughness values than that of conventional chromium coating. Although more MoS{sub 2} particles will be incorporated into the electrodeposits when the solid content of the bath increases, chromium cannot be electrodeposited from baths containing high amounts of MoS{sub 2} particles. Application of cationic surfactant promotes incorporation of particles into the Cr metallic matrix. Moreover, the presence of surfactant in the bath results in the formation of coatings with less microcracks. All the composite coatings have more hardness values than that of conventional chromium coating; maximum hardness is attributed to the coatings that were electrodeposited from baths containing no surfactant. The corrosion test results revealed that the smooth coatings containing more MoS{sub 2} particles and less microcracks exhibit more corrosion resistance than the other ones.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Refill Friction Stir Spot Welding Dissimilar Al/Mg Alloys

Dissimilar Al/Mg alloys were joined by refill friction stir spot welding (RFSSW) in this work. The effect of sleeve plunge depth on microstructure and mechanical properties of the joints was studied. The results showed that sound joint can be obtained at sleeve plunge depth of 2.4 mm. Intermetallic compounds (IMCs) layer, formed by the liquid eutectic phase, were observed at both the sleeve-affected zone and joint center. The IMC at the pin-affected zone was thicker than that at the sleeve-affected zone because of its flow characteristic. Less liquid eutectic phase formed during RFSSW when joint using Mg as the upper sheet because the oxide layer on the Al sheet was hard to break, resulting to thinner IMC layer. The maximum load of 3.6 kN was obtained at 2.6 mm when the Al alloys served as the upper sheet, and the maximum failure of 3.6 kN was also obtained at 2.4 mm when the Mg alloys served as the upper sheet. The RFSSW joint presented shear fracture mode. The XRD patterns showed that the IMC of Al{sub 3}Mg{sub 2} and Al{sub 12}Mg{sub 17} formed inside the joint.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Friction Stir Lap Welding 0.8-mm-Thick 2024 Aluminum Alloy with the Assistance of Stationary Shoulder

In this work, 0.8-mm-thick 2024 aluminum alloy was friction stir lap welded with the assistance of a stationary shoulder system. The joint surface formation, microstructure and mechanical properties of the welded joints were studied. The results showed that sound joints without defect could be obtained at a wide parameter range because stationary shoulder increased the material flow during welding. The stationary shoulder decreased the joint roughness from 125.5 to 58.9 µm. A thickness reduction of 4% was achieved at a welding speed of 200 mm/min. The joint fabricated by the stationary shoulder system had superior lap shear properties compared to the joint fabricated using the conventional tool. A high failure load of 7440 N was achieved at welding speed of 200 mm/min. The joint presented tensile fracture mode and the fracture morphology showed typical ductile fracture.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Cryogenic Treatment of CoCrFeMnNi(NbC) High-Entropy Alloys

The effect of cryogenic treatment on the microstructure and mechanical properties of CoCrFeMnNi and CoCrFeMnNi(NbC) high-entropy alloys was investigated during annealing. The heat-treated samples were characterized by optical microscopy, scanning electron microscopy–wavelength-dispersive x-ray spectroscopy, x-ray diffraction technique, differential scanning calorimetry, Vickers hardness testing and tensile testing. The results showed a single-phase FCC crystal structure matrix in both alloys during cryogenic treatment and annealing. Cryogenic treatment altered the recrystallization behavior of CoCrFeMnNi high-entropy alloy, while it did not influence the recrystallization of CoCrFeMnNi(NbC) high-entropy alloy. It was also found that cryogenic treatment changed the precipitation behavior of CoCrFeMnNi(NbC) high-entropy alloy during annealing. In both studied high-entropy alloys, the mechanical testing indicated that the cryogenic treatment can effectively reduce the yield strength of cold-rolled samples after annealing. This was primarily attributed to the effect of cryogenic treatment in enhancing crystalline defects annihilation. Furthermore, the cryogenic treatment increased the ultimate tensile strength of CoCrFeMnNi(NbC). A lager plastic deformation and precipitates were considered as the main reasons for the higher ultimate tensile strength.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Phase Stability Through Machine Learning

Understanding the phase stability of a chemical system constitutes the foundation of materials science. Knowledge of the equilibrium state of a system under arbitrary thermodynamic conditions provides valuable information about the types of phases that are likely to be synthesized and how to get there. Accessing the phase diagram in a materials system provides one with the information necessary to design materials and microstructures with optimal properties. While the materials science community has long been focused on exploiting this knowledge to navigate the materials space, recent advances in machine learning (ML) and artificial intelligence (AI) have provided the community with novel ways of interrogating the materials thermodynamics space. Furthermore, this work presents some of the most recent advances in ML/AI applied to phase stability and thermodynamics of materials. Prof. John Morral always had a passion for understanding and teaching the fundamental characteristics of phase diagrams. This review is written to honor his memory.

36 MATERIALS SCIENCE↗
DOE OSTI2018

A Review of Finite Element Method Models for Nuclear Graphite Applications

Graphite components serve as structural support and as a neutron moderator in multiple nuclear power stations and is also a prospective material in Generation IV reactor concepts. The environment (e.g. high temperature and intense radiation) within a graphite core changes the geometry, microstructure and material properties of the graphite components, that could limit the lifetime (i.e. safe operation) of a reactor. Some of the assessments made for graphite reactor core components include Finite Element Method (FEM) simulations. These simulations are used to estimate the stress state and strain state and probability of failure of irradiated graphite components. FEM also forms part of the validation of measurements or as a complementary technique to experimental procedures in graphite research. A comprehensive overview of FEM methodologies is provided in this review, including: FEM software, basics steps to set up a FEM model, and analytical solutions used to validate simulations for this field of study. In conclusion, the objective of this paper is to inform researchers in the different available FEM techniques and tools used in the research of nuclear graphite.

42 ENGINEERING↗
DOE OSTI2024

Effects of Post-sintering Annealing on (NdLa)-(FeCo)-B Magnets

A common limitation of La substitutions into (Nd, La) 2 Fe 14 B magnets is the reduction of the anisotropy field (H a ), which decreases magnet coercivity (H cj ). In this study, adding a small amount of Pr-Cu to a La-containing neo magnet may modify the grain boundary (GB), which can help recover a fraction of the degraded H cj . An optimal GB modification requires a carefully designed post-sinter heat treatment, which is the focus of this work on characterizing the effects of multi-step post-sintering annealing on the evolutions of microstructure and magnetic properties. We find that Nd and Cu concentrations at GBs and triple junctions (TJs) increase when the annealing temperatures are lowered. Annealing temperatures of 580°C and 480°C (near rare-earth-rich eutectic temperatures) enabled the development of a thick and continuous GB phase, which helps to magnetically decouple the grains, and, thus, enhance H cj . For the alloy with 25% Nd replaced by La, and with the addition of 7.5 wt.% of Pr 68 Cu 32 as GB modifier, the optimized multi-step post-sinter annealing improved the H cj from 4.8 kOe to 9 kOe.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Novel vertically aligned nanocomposite of Bi 2 WO 6 -Co 3 O 4 with room-temperature multiferroic and anisotropic optical response

A review of a new vertically aligned nanocomposite (VAN) structure based on two-dimensional (2D) layered oxides has been designed and self-assembled on both LaAlO 3 (001) and SrTiO 3 (001) substrates. The new VAN structure consists of epitaxially grown Co 3 O 4 nanopillars embedded in the Bi 2 WO 6 matrix with a unique 2D layered structure, as evidenced by the microstructural analysis. Physical property measurements show that the new Bi 2 WO 6 -Co 3 O 4 VAN structure exhibits strong ferromagnetic and piezoelectric response at room temperature as well as anisotropic permittivity response. This work demonstrates a new approach in processing multifunctional VANs structure based on the layered oxide systems towards future nonlinear optics, ferromagnets, and multiferroics.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2023

Rapid discovery of high hardness multi-principal-element alloys using a generative adversarial network model

Multi-principal element alloys (MPEAs) continue to gain research prominence due to their promising high-temperature microstructural and mechanical properties. Recently, machine learning (ML) and materials informatics have been used extensively for screening MPEAs, however, most of these efforts were focused on constructing classification and regression models for predicting phase stability and mechanical properties of known compositions. These approaches may accelerate the screening process but optimizing new compositions with desirable properties within a practical time frame from an infinitely large design space of MPEA systems remains a grand challenge. To tackle this composition optimization challenge, a generative adversarial network coupled with a neural-network ML model was utilized to design MPEAs by filtering compositions that have high hardness. Even in a high-dimensional space with 18 elements as descriptors, the ML model was able to generate optimized compositions from which one composition was found to have 10% higher hardness (941 HV) than the maximum in the training data (857 HV). Density-functional theory was used to provide thermodynamic and electronic insights to higher hardness of the new MPEA found. The present work can optimize compositions from a wide design space of 18 elements (including W, Ta and Nb) that presents an opportunity to synthesize new compositions for applications ranging from corrosion-resistant alloys to nuclear materials. Here the findings suggest that generative ML can greatly accelerate materials discovery by identifying novel compositions, which can serve as a data-informed tool to guide experiments.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Mechanisms for high creep resistance in alumina forming austenitic (AFA) alloys

Castable alumina forming austenitic (AFA) alloys have demonstrated superior creep life and oxidation resistance at temperatures exceeding 800⁰C. Despite the success in the applicability of these alloys in extreme environments, there is a limited understanding of the deformation modes and the influence of each alloying element guiding the alloy design strategies that could further enhance the creep strength of these AFA alloys, particularly at temperatures at and above 900⁰C. In this study, we reveal the mechanism underpinning the superior creep performance of castable AFA alloys that involves suppressing primary carbide formation through minor compositional modification. This approach results in a three-fold increase in creep strength at 900⁰C and 50 MPa. Here, by employing integrated characterization techniques, we analyzed the microstructures of two AFA alloys, both before and after the creep process. We discovered that the suppression of primary carbides permits the in-situ clustering of now-available interstitial elements such as C, Si, and O during high-temperature creep. This improved solid solution strengthening and reduced stacking fault energy of the alloy. Moreover, it also enabled controlled secondary carbide formation during testing, further improving the creep resistance. These findings underline the important interplay between alloy composition, microstructure, and creep properties, and offer a promising design strategy for developing economical high-temperature Fe-based alloys suitable for advanced applications.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Review of Computer-Aided Manufacturing (CAM) strategies for hybrid directed energy deposition

Hybrid additive manufacturing intertwines both additive and subtractive manufacturing layer by layer to digitally fabricate parts with complex geometries, improved surface finish and tight dimensional accuracies, the sum of which is difficult to obtain with any single process. Computer-Aided Manufacturing (CAM) software is required to orchestrate the machine toolpathing for both the deposition as well as the machining processes and is crucial for the successful fabrication of high quality structures. Additionally, CAM requires substantial operator input to account for challenging aspects of each fabricated structure. For example, deciding at which layer of deposition will the machining process continue to maintain access to complex cavities for finishing - internal features that would otherwise be unfinishable due to reach limitations or obstructions. Moreover, of the many commercially-available hybrid systems, each has a unique kinematic environment which can benefit from specific optimization of toolpath planning and substantial research has directly correlated toolpathing with the microstructure evolution, mechanical properties, porosity and residual stress state of the final fabricated part. This review explores the available strategies for CAM in the context of hybrid direct energy deposition, discusses the advantages and disadvantages of each and considers future CAM trends for this transformational digital manufacturing technology.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Effect of Zr and Sc additions on coarsening- and creep resistance of AlSi10Mg fabricated by laser powder bed fusion

Microstructure and creep properties are studied in a eutectic AlSi10Mg alloy modified with Zr and Sc additions (Al-9.8Si-0.32Mg-0.70Zr-0.23Sc, wt%) manufactured through laser powder-bed fusion (L-PBF). Three types of Zr/Sc-bearing powders - elemental, master-alloy, and pre-alloyed - are employed in the fabrication process, with the pre-alloyed powders providing the highest incorporation of Zr and Sc in the Al matrix. Here, the as-printed alloy exhibits a fine cellular Al-Si eutectic structure which fragments and coarsens into micron-sized Si particles during aging at 300 ºC, leading to a steady drop in alloy microhardness between 0.1 and 1000 h. Coarsening of the eutectic Si phase during aging is not measurably affected by Zr and Sc in solid solution, which precipitate during aging and increases strength, compensating weakening from Si coarsening between 1 and 200 h at 300 ºC. Atom-probe analysis in the peak-aged condition (96 h/300 °C) confirms the presence of Al 3 (Sc,Zr) secondary nano-precipitates with an average radius of 1.0 nm and some Si solubility. Micron-sized grains are present throughout the alloy, with ultra-fine-grained regions at the melt pool boundaries, neither of which coarsen during long-term aging at 300 ºC. Under creep conditions at 300 °C, the Zr/Sc-bearing alloy with Al 3 (Sc,Zr) nano-precipitates exhibits power-law behavior, with a high apparent stress exponent (n a = 9) and a high threshold stress (σ th = 43 MPa), exhibiting nearly double the strength of a Zr/Sc-free AlSi10Mg control alloy (σ th = 22 MPa).

36 MATERIALS SCIENCE↗
DOE OSTI2022

Microstructure and hardness evolution induced by annealing of ion irradiated LiTaO 3

We report the evolution of the microstructure and mechanical properties of low-energy heavy-ion-irradiated LiTaO 3 crystals annealed at various temperatures was investigated by transmission electron microscopy (TEM) observations and nanoindentation tests to extend the applications of irradiated LiTaO 3 crystals. Before annealing, randomly distributed voids formed in an approximately 200 nm thick region at the end of the ion irradiation range, which was attributed to preferential absorption of interstitials by the amorphous-crystalline interface. After annealing, a new directional diffusion path of defects was identified, resulting in a void string. Furthermore, void string diffusion to the free surface was also found during the annealing temperature increase process, which offers a potential application in designing custom sized-thickness exfoliation at the nanoscale. Meanwhile, two competing processes were identified during the annealing process: epitaxial recrystallization from the amorphous-crystalline interface and grain nucleation process in the amorphous region, which formed phases different from the matrix crystal structure, resulting in an interaction between them. Furthermore, the hardness of irradiated samples was also found to be affected by the annealing process; in particular, a hardness decrease induced by the interstitial Fe ions in the recrystallized region was also confirmed, which can improve the processability of samples for further application.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Carbonation dynamics of hydrated alite revealed by electron microscopy

CO 2 sequestration in concrete is crucial to relieve the environmental burden, while the carbonation mechanisms remain unclear. Here, we explored the carbonation dynamics of alite hydrates through electron microscopy. We discovered that calcite is the main phase of carbonate crystals throughout the entire carbonation period in the alite system. Further, the shape evolution of calcite crystals was captured: spindle carbonates initially formed on C-S-H substrate and then transformed into rhombohedrons; Intermediate states such as polyhedral particles and layered rhomboids were also observed. Based on our quantitative calculations, the growth rate of calcite particles was determined approximately 0.2 μm/day, which may be affected by the relative concentration between calcium ions and CO 2 source. A direct relation between the microstructure and mechanical properties of calcite was uncovered using atomic force microscopy. Furthermore, we found that the morphology development of calcite crystals during carbonation may be explained by the surface energy variation of different facets. This work suggests a unique approach to track carbonation kinetics and provides new opportunities to unveil underlying carbonation mechanisms at the nanoscale.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Instabilities and phase transitions in architected metamaterials: a gradient-enhanced continuum approach

Architected metamaterials such as foams and lattices exhibit a wide range of properties governed by microstructural instabilities and emerging phase transitions. Their macroscopic response–including energy dissipation during impact, large recoverable deformations, morphing between configurations, and auxetic behavior–remains difficult to capture with conventional continuum models, which often rely on discrete approaches that limit scalability. In this work, we propose a nonlocal continuum formulation that captures both stable and unstable responses of elastic architected metamaterials. The framework extends anisotropic hyperelasticity by introducing nonlocal variables and internal length scales reflective of microstructural features. Local polyconvex free-energy models are systematically augmented with two families of non-(poly)convex energies, enabling both metastable and bistable responses. Implementation in a finite element framework enables solution using a hybrid monolithic–staggered strategy. Simulations capture densification fronts, forward and reverse transitions, hysteresis loops, imperfection sensitivity, and globally coordinated auxetic modes. Overall, this framework provides a robust foundation for accelerated modeling of instability-driven phenomena in architected metamaterials, while enabling extensions to anisotropic, dissipative, and active systems as well as integration with data-driven and machine learning approaches.

42 ENGINEERING↗
DOE OSTI2023

A sensitivity analysis of twinning crystal plasticity finite element model using single crystal and poly crystal Zircaloy

The popularity of crystal plasticity finite element method (CPFEM) models is increasing due to their ability to predict the mechanical response of crystalline materials such as metals and metal alloys more accurately than traditional continuum mechanics models. This is since the crystal plasticity models consider the effect of atomic structure, microstructural morphology, and properties of individual grains. These CPFEM models use a large number of material parameters in order to capture the mesoscale physics which comes with the downside of the tedious calibration process. In this paper, a CPFEM code was developed to include the twinning induced grain reorientation and subsequent crystallographic slip for HPC material. The developed code is incorporated in a large-scale, parallelized nonlinear solver WARP3D. Further, a sensitivity analysis with respect to 22 material parameters was then conducted using single crystal and polycrystal representative volume element (RVE) of Zircaloy material. Loading was applied along five different crystallographic orientations for single crystal RVE and along three directions namely, rolling (RD), transverse (TD), and normal (ND) direction for polycrystal RVE. Results obtained from the sensitivity analysis were used for the calibration of material parameters for Zircaloy. Finally, developed code along with calibrated material parameters was used to investigate the effect of the hydride phase formation in Zircaloy which is a typical case observed for nuclear applications. It was found that the volume fraction of the hydride phase has a significant impact on the mechanical properties of Zircaloy.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Mechanical characterization of fine-grain dispersion-strengthened tungsten as a plasma facing material

Field-Assisted Sintering Technology (FAST) was used to produce fine-grained, dispersion-strengthened tungsten (W) materials. Investigated materials 4138, 4353, and 4355 composed of 3 wt% ZrC sintered at 1800 °C, 5 wt% ZrC sintered at 1800 °C, and 3 wt% ZrC sintered at 2000 °C, respectively. They were compared against ITER-grade W. A series of mechanical and thermal property testing and microstructure studies were conducted to study them as a potential plasma facing material (PFM) for fusion reactors. Hardness testing showed that manufacturing conditions substantially altered hardness. Material 4355 had an average HV10 value of 497.2 ± 16.8, slightly higher than ITER-grade at 378.5 ± 40.3. However, material 4353 was substantially higher with an HV10 value of 738.9 ± 31.7 over the investigated temperature range. Electron Backscatter Diffraction (EBSD) analysis showed that FAST produced substantially smaller grains than the hot-rolled ITER-grade W material, offering notable control over grain size. Materials 4353 and 4355 had grain sizes of 0.44 ± 0.20 µm and 3.67 ± 0.89 µm, respectively, whereas ITER-grade 27.14 ± 19.76 µm at room temperature. The fine grain structures showed no net coarsening after 1 hr. anneals up to 1800 °C, several hundred degrees above the 1100 – 1500 °C recrystallization range reported for conventional W. Inverse application of the Zener pinning relationship to the measured grain sizes indicates that these two FAST sintering conditions produce markedly different effective dispersoid populations, with effective particle diameters of approximately 90 nm at a peak sintering temperature of 1800 °C and approximately 460 nm at 2000 °C, respectively. This result demonstrates that the FAST thermal condition itself, and not the nominal ZrC content alone, governs the pinning effectiveness of the dispersion. Thermal diffusivity measurements support this finding independently. Materials of identical composition sintered at different temperatures differ by approximately 19% in measured thermal diffusivity with statistically indistinguishable density, while materials of different composition and sintering temperature converge to within approximately 2%. At a representative divertor heat flux of 10 MW/m², the lower thermal conductivity of the fine-grained materials corresponds to approximately 28 to 33 °C per millimeter of armor thickness relative to ITER-grade W, traded against a substantially larger margin to recrystallization-driven degradation. While high temperature tensile testing revealed likely contamination that motivates refinement of the manufacturing process, FAST-produced, fine-grained, dispersion-strengthened W offers process-controlled microstructural stability well above the operating temperatures of conventional W and supports its continued development as a PFM for economically viable commercial fusion power.

Parker, Gabe [ORNL] (ORCID:0000000190394100)↗