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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2017

Enhancement of bronze alloy surface properties by FSP second-phase particle incorporation

This study presents results of an experimental study to evaluate friction stir processing (FSP) with and without hard second-phase particle incorporation as a means to enhance surface properties and wear performance of C86300 manganese bronze alloy. FSP of flat bronze alloy specimens was conducted with hardened H-13 tool steel to create a 3-mm-thick processed surface layer. The process was also used to incorporate B 4 C particles, thereby creating a metal-matrix composite layer on the alloy surface. FSP alone was observed to produce substantial reduction in grain size (from an initial value of 350 mu m to 1-5 μm). FSP without particle incorporation resulted in modest surface hardening due to grain refinement and dispersion hardening. Under lubricated contact in block-on-ring testing with a hardened steel counter face, FSP produced substantial reduction (about 3X) in bronze wear after polishing of processing surface roughening. FSP with hard B 4 C second-phase particle incorporation further reduced wear by up to 20X. The improvement in wear behavior is attributed to grain refinement and load shielding by second-phase particles, as determined by wear mechanism analysis.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Fabrication of 7075-0.25Sc-0.15Zr Alloy with Excellent Damping and Mechanical Properties by FSP and T6 Treatment

This study investigated the effects of Sc and Zr additions, friction stir processing (FSP), and subsequent solid solution and artificial aging (T6) treatment on the microstructure, damping capacity, and mechanical properties of 7075 Al alloy. The minor Sc and Zr additions promoted the grain refinement of this alloy during FSP and inhibited the growth of fine equiaxed grains in the FSP sample during subsequent T6 treatment. Thus, the fine equiaxed grain structure and high density of the η′ precipitated phase were simultaneously obtained in the 7075 Al alloy containing Sc and Zr after FSP and T6 treatment, and this sample exhibited superior mechanical properties and damping capacity to those of the 7075 Al alloy after T6 treatment. This work provides an effective strategy for preparing Al alloys with excellent damping capacity and mechanical properties.

36 MATERIALS SCIENCE↗
DOE OSTI2017

FLOW TESTING AND ANALYSIS OF THE FSP-1 EXPERIMENT

The U.S. High Performance Research Reactor Conversions fuel development team is focused on developing and qualifying the uranium-molybdenum (U-Mo) alloy monolithic fuel to support conversion of domestic research reactors to low enriched uranium. Several previous irradiations have demonstrated the favorable behavior of the monolithic fuel. The Full Scale Plate 1 (FSP-1) fuel plate experiment will be irradiated in the northeast (NE) flux trap of the Advanced Test Reactor (ATR). This fueled experiment contains six aluminum-clad fuel plates consisting of monolithic U-Mo fuel meat. Flow testing experimentation and hydraulic analysis have been performed on the FSP-1 experiment to be irradiated in the ATR at the Idaho National Laboratory (INL). A flow test experiment mockup of the FSP-1 experiment was completed at Oregon State University. Results of several flow test experiments are compared with analyses. This paper reports and shows hydraulic analyses are nearly identical to the flow test results. A water velocity of 14.0 meters per second is targeted between the fuel plates. Comparisons between FSP-1 measurements and this target will be discussed. This flow rate dominates the flow characteristics of the experiment and model. Separate branch flows have minimal effect on the overall experiment. A square flow orifice was placed to control the flowrate through the experiment. Four different orifices were tested. A flow versus delta P curve for each orifice is reported herein. Fuel plates with depleted uranium in the fuel meat zone were used in one of the flow tests. This test was performed to evaluate flow test vibration with actual fuel meat densities and reported herein. Fuel plate deformation tests were also performed and reported.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Rapid grain refinement and compositional homogenization in a cast binary Cu50Ni alloy achieved by friction stir processing

Friction stir processing (FSP) has been increasingly adopted for joining and processing materials in automotive, aerospace and industrial construction. During FSP a dynamic competition between high-speed shear deformation and deformation-induced heating brings about a complex competition between multiple dynamic microstructural evolution mechanisms making it difficult to predict the microstructural evolution pathway. Hence, improved understanding of microstructural evolution mechanisms during FSP can be beneficial for continued growth in the adoption of FSP for demanding applications of future. Towards this goal, this study uses a model binary Cu – 50 at.% Ni alloy to clarify the effect of single and double pass FSP on the microstructural evolution of a coarse grained and compositionally heterogeneous cast microstructure. High energy synchrotron X-ray diffraction, electron backscatter diffraction, and nanoindentation are used to clarify the microstructural evolution due to FSP. The process of compositional homogenization of as-cast segregations is studied by energy dispersive spectroscopy and atom probe tomography. Our results show that a single fast FSP pass at 30 mm.s -1 produces a 100 µm deep layer of submicrometric and hall-petch hardened CuNi grains. The initial cast compositional heterogeneities in a micrometric scale is rapidly transformed to nano-sized domains, mainly confined at grain boundaries. Double pass FSP increases the penetration depth of the processed layer and leads to a 2.9 times grain growth relative to single pass FSP. Grain fragmentation, discontinuous dynamic recrystallization, grain growth, and twinning mechanisms are discussed. In conclusion, these results highlight the value of FSP for ultrafast grain refinement and compositional homogenization of cast alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Rapid surface hardening and enhanced tribological performance of 4140 steel by friction stir processing

Tribological performance of steel materials can be substantially enhanced by various thermal surface hardening processes. For relatively low-carbon steel alloys, case carburization is often used to improve surface performance and durability. If the carbon content of steel is high enough (>0.4%), thermal treatments such as induction, flame, laser, etc. can produce adequate surface hardening without the need for surface compositional change. This paper presents an experimental study of the use of friction stir processing (FSP) as a means to hardened surface layer in AISI 4140 steel. The impacts of this surface hardening process on the friction and wear performance were evaluated under both dry and lubricated contact conditions in reciprocating sliding. FSP produced the same level of hardening and superior tribological performance when compared to conventional thermal treatment, using only 10% of the energy and without the need for quenching treatments. With FSP surface hardness of about 7.8 GPa (62 Rc) was achieved while water quenching conventional heat treatment produced about 7.5 GPa (61 Rc) hardness. Microstructural analysis showed that both FSP and conventional heat treatment produced martensite. Although the friction behavior for FSP treated surfaces and the conventional heat treatment were about the same, the wear in FSP processed surfaces was reduced by almost 2× that of conventional heat treated surfaces. Furthermore, the superior performance is attributed to the observed grain refinement accompanying the FSP treatment in addition to the formation of martensite. As it relates to tribological performance, this study shows FSP to be an effective, highly energy efficient, and environmental friendly (green) alternative to conventional heat treatment for steel.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Friction Stir Processing on the Microstructure, Damping Capacity, and Mechanical Properties of Al-Si Alloy

Friction stir processing (FSP) was conducted on an Al-Si casting alloy. The Si phase and Al grains of an Al-Si casting alloy were refined through FSP. Furthermore, FSP with high rotation rate led to the precipitation of Mg and Si atoms and the formation of Mg{sub 2}Si phase in the Al-Si alloy. Precipitation improved the low-strain damping capacity but deteriorates high-strain damping capacity of the FSP sample at room temperature. At low rotation rate, the FSP sample exhibited excellent high-temperature damping capacity mainly because of its fine grain structure and the low density of its pinning points. The plastic instability of the Al-Si alloy was eliminated by FSP because of the refinement of the Si phase. The increase in the strength of each FSP sample was attributed to the increase in second-phase and boundary strengthening effects. Thus, the mechanical properties and damping capacity of Al-Si were enhanced after FSP.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Effects of in-process cryocooling on metallurgical and mechanical properties of friction stir processed Al7075 alloy

Highlights: • For in-process cryocooling (IPC) during FSP, an efficient cooling fixture was designed & fabricated. • FSP of Al7075 alloy with IPC setup suppressed precipitate coarsening as well as grain growth. • Nanosize η′ precipitates (20–30 nm) in IPC condition increased work hardening capacity & strength. • Simultaneous improvement in ductility & strength occurred for sample FSPed with IPC. - Abstract: Friction stir processing (FSP) of heat treatable aluminum alloys is reported to deteriorate strength and hardness properties in spite of huge grain size refinement. The improvement in strength due to the grain size refinement after FSP could not be able to offset the reduction in strength due to coarsening or dissolution of the strengthening precipitate(s). To overcome this, the present work investigates an effective way of heat rejection from the FSP zone to control the precipitate evolution besides the grain size refinement during FSP of Al7075 alloy. The FSP was carried out with standardized process parameters (i.e. 720 rpm, 65 mm/min traverse speed) under two different cooling environments: (i) at normal air cooling and (ii) by rushing a chilled mixture (−30 °C) of liquid nitrogen and methanol through the bottom of the backing plate. Microstructural evolution was examined through optical, scanning and transmission electron microscopy and electron backscatter diffraction to confirm the grain size and morphology of precipitate(s) formed. The in-process cryocooling during the FSP led to 65 and 72% improvement in the Vickers hardness and tensile strength, respectively, in comparison to the solutionized base metal. The results have been analyzed in terms of precipitate interface characteristics and its strengthening effect, Hall–Petch strengthening due to grain size reduction and tradeoff between them.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Microstructure-refinement–driven enhanced tensile properties of high-pressure die-cast A380 alloy through friction stir processing

This work employs friction stir processing (FSP), a well-known severe plastic deformation technique, to selectively modify the microstructure of thin-walled, high-pressure die-cast (HPDC) aluminum alloy A380, a major HPDC alloy fabricated in the die casting sector. FSP effectively breaks down Al dendrites and acicular Si particles, creating a homogenized distribution of equiaxed Si particles in the aluminum matrix. After FSP, the refined Si particles (~1.5 µm) are smaller than the eutectic Si particles (3–8 µm) in HPDC condition. In addition, interparticle distance has decreased almost 50% compared to dendritic arm spacing, and FSP has reduced the aspect ratio of Si particles to ~2. Furthermore, FSP eliminates porosity, and breaks down needle-like second-phase Fe-Mn and Cu-rich particles, yielding a refined, homogeneous distribution. The FSP-induced microstructural refinement and porosity reduction improve bulk yield strength and ductility by 23% and 66%. Tensile properties are enhanced beyond those of the die skin of the HPDC plate, and the alloy possesses lower defect density and a highly refined microstructure. This study establishes the viability of FSP as a tool for microstructure modification and mechanical property improvement for HPDC Al alloys for the light-weighting goal of the automotive industries.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Effects of friction stir processing and minor Sc addition on the microstructure, mechanical properties, and damping capacity of 7055 Al alloy

Highlights: • Good mechanical and damping properties were obtained in the 7055 after FSP and Sc addition. • The strengthening and damping mechanisms of FSP 7055(-Sc) were analyzed. • FSP and Sc addition were found to be strategy of preparing 7xxx alloys with well damping and mechanical properties. - Abstract: This study investigated the effects of friction stir processing (FSP) and addition of 0.25% (mass ratio) Sc on the microstructure, mechanical properties, and damping capacity of AA 7055 alloy. Microstructure analyses revealed that a low tool rotation rate of 300 rpm effectively inhibited the grain coarsening in the recrystallization of the alloy during FSP. Sc addition prevented the coarsening of grains and precipitated η phase and the annihilation of dislocations in the FSP AA 7055 alloy. After being subjected to FSP at 300 rpm, the AA 7055 alloy containing Sc exhibited good mechanical and damping properties, which were mainly attributed to the fine recrystallized grain structure, fine precipitated η phase, and large number of nano-sized Al{sub 3}(Sc, Zr) particles located at the grain boundaries and dislocations. This work provides an effective strategy for preparing commercial Al alloys with excellent damping capacity and mechanical properties.

36 MATERIALS SCIENCE↗
DOE OSTI2018

High damping capacity of Al alloys produced by friction stir processing

Highlights: • The damping capacity of age/non-age hardened Al alloys can be improved by FSP with low rotation rates. • The damping capacity of the FSP samples decreased with increasing the grain size, and did not depend on the alloy type. • This work suggests the potential of fabricating commercial Al alloys with good damping properties by FSP. - Abstract: Friction stir processing (FSP) was performed on both age-hardened and non-age-hardened Al alloys, with excellent damping properties obtained. The improved room temperature damping capacity of the FSP Al alloys can be mainly attributed to their low amount of solute atoms and the uniform distribution and high density of incoherent phases. The FSP Al alloys also exhibited improved high temperature damping capacity due to their equiaxed grain structure. The grain refinement and grain boundary pinning phase can further optimize the damping property of the FSP Al alloys. This work provides an effective strategy to improve the damping capacity of commercial Al alloys, which are regarded as low damping materials.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Development of microstructure and texture during single and multiple pass friction stir processing of a strain hardenable aluminium alloy

Highlights: • Development of microstructure and texture during single and multiple pass FSP of a strain hardenable aluminium alloy • Strain induced boundary migration (SIBM) is the dominant nucleation mechanism for recrystallization • Weak crystallographic texture development influenced by SIBM with the relative dominance of shear texture components • Stable microstructure and texture development after multiple pass FSP • FSP is a promising method for the secondary processing of strain hardenable aluminium alloys - Abstract: In the present study, microstructure and texture development during single and multiple pass friction stir processing (FSP) of a strain hardenable wrought AlMg alloy (AA5086) was investigated. Subtle differences were observed while comparing with heat treatable alloys in the nucleation mechanism of the recrystallized microstructure observed in the nugget zone. Strain induced boundary migration was the dominant mechanism of microstructure evolution in the alloy, which influenced the crystallographic texture development by weakening it. Micro-texture measurements reveal variations in the crystallographic texture along the thickness of the sample. Recrystallization texture components were observed in the nugget zone indicative of a pronounced static recrystallization in the alloy as compared to the heat treatable alloys. Bulk texture measurements within the nugget zone of the optimally processed sample reveal a relatively dominant C component of shear texture. Average grain size in the nugget zone remained the same and the bulk crystallographic texture components were retained during multiple-pass FSP. The lower strain energies involved and the enhanced recovery processes due to the high temperature materials processing of the alloy during FSP resulted in a stable microstructure and texture. In summary, FSP could be promoted as a competent and suitable secondary processing technique for the bulk production of ultra-fine-grained materials in strain hardenable aluminium alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Understanding the effect of friction stir processing on electrical steel: Microstructural changes and mechanical transformations

Raising Si beyond 3.5 wt% reduces core loss but embrittles electrical steels, constraining processing and application. Here we assess friction stir processing (FSP) as a solid‑state route to enable Fe–4.0 wt% Si with improved mechanical performance. Temperature‑controlled FSP with a PcBN tool produced a defect‑free processed zone. SEM/EBSD revealed dynamic recrystallization and grain refinement from an average 110 μm in the base material to ∼20 μm in the processed region, with ∼ 80% of grains < 40 μm and a reduction in high‑angle boundary fraction to ∼65% (vs >85% in the base). Comparative mechanical property analysis shows a moderate increase in yield strength in FSP samples relative to the base material, with a significant improvement in ductility (∼35–50%). Post‑fracture EBSD identified 60° twin boundaries in the base while sub-grain formation with elevated KAM in the FSP sample. Fractography revealed a shift from quasi‑cleavage in the Base-faceted planes with river patterns, steps, and occasional secondary cracks—to ductile micro void coalescence after FSP. Following FSP, the material retains soft‑magnetic behavior, with modest shifts in saturation magnetization consistent with grain refinement and stored strain, accompanied by a clear gain in formability. These results indicate that FSP provides a viable route to deploy higher‑Si electrical steels with concurrent gains in strength and ductility.

Electrical steel↗
DOE OSTI2019

Developing the Irradiation Plan for U-10Mo LEU Fuel Qualification for the Advanced Test Reactor

The Department of Energy (DOE), National Nuclear Security Administration’s Office of Material Management and Minimization (M3) mission is to convert, remove, and dispose of vulnerable nuclear material located at civilian sites worldwide. As part of its mission, M3’s Office of Convert works around the world to convert research reactors and isotope production facilities to non-weapon-usable nuclear material, both domestically and abroad. In support of this, the Office of Convert is working with the Idaho National Laboratory (INL) to develop and qualify new fuels and technologies to support conversion efforts domestically and abroad. The INL also supports the Office of Convert by working on converting the Advanced Test Reactor (ATR) and the Advanced Test Reactor Critical (ATRC) from using High Enriched Uranium (HEU) fuel to Low Enriched Uranium (LEU) fuel. To ensure the viability of ATR LEU fuel, the fuel system should meet a similar functional and operational envelope as the current HEU fuel. A series of irradiation tests of the U-10Mo LEU fuel system is required to support the qualification of the fuel system for use in the ATR and several other U.S. High-Performance Research Reactors (USHPRRs). These irradiation tests include: • Mini-Plate tests (MP-1, MP-2, and MP-ATR), • Full-Size Plate tests (FSP-1, and FSP-ATR), and • Element Tests (ET-1, ET-2, and ET-3). The MP tests will use multiple small-scale samples that will provide sufficient data across a wide variety of irradiation conditions to qualify the fuel. The FSP tests will use a small number of full-sized fuel plates to confirm the MP test results are representative of the prototypic plate geometry performance. The MP and FSP irradiation tests occur in ATR test locations. The ETs will use full-sized fuel elements located in ATR core driver positions to explore the full operating ranges of the ATR and other USHPRRs and to confirm that the MP and FSP test results are representative of the prototypic element geometry performance. The established testing functional and operational requirements of MP-1, MP-2, FSP-1, and ET 1 achieve the base fuel qualification needs of the USHPRRs, while the high-level purposes of MP-ATR, FSP ATR, ET 2, and ET-3 are focused on demonstrating U-10Mo fuel for ATR use.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Exploring the Microstructure-Property Relationship of Mg-Al-Mn alloys enhanced via Friction Stir Processing

Friction Stir Processing (FSP) is a solid-state thermomechanical processing technique that enables local grain refinement, densification, and homogenization of microstructure in metallic components. Here, FSP is applied to thin sheets of high-pressure die cast AM60 to address the porosity and heterogeneities inherent to the casting process. In this work, microstructure characterization is correlated to improvements in the static mechanical properties of the Mg-Al-Mn alloy system at various FSP processing conditions. Notably, there is a significant increase in the ductility and ultimate tensile stress of system following FSP. The dominant deformation mechanisms for the as-cast material and the FSP material are investigated. Finally, the fatigue life improvement is correlated to microstructure modifications that may lead to distinct behavior in crack initiation and crack propagation for the as-cast and FSP material.

Garcia, David↗
DOE OSTI2018

Microstructure and Mechanical Properties of Friction Stir Process Derived Al-TiO{sub 2} Nanocomposite

Aluminum-based composites have many advantages over their conventional counterparts. A major problem in such composites is the clustering of particles in the matrix. Friction stir processing (FSP) can homogenize particle distribution in aluminum-based composites. In this study, unannealed TiO{sub 2} particles were used to prepare Al-TiO{sub 2} nanocomposite using FSP. The TiO{sub 2} particles, about 1 µm, were dispersed into an aluminum matrix by 6 passes of FSP. The TiO{sub 2} particles were fractured by multiple FSP passes, leading to a nano-size particle distribution in the matrix. Nanoscale dispersion was confirmed by scanning electron microscopy and transmission electron microscopy. The fractured TiO{sub 2} particles reacted with the aluminum matrix to form Al{sub 3}Ti intermetallic and Al{sub 2}O{sub 3} ceramic. The progression of the Al-TiO{sub 2} reaction from the fourth to the sixth pass of FSP was revealed by x-ray diffraction. Due to the nanoscale dispersion, the yield and ultimate tensile strength of the composite increased to 97 and 145 MPa, respectively. Ductility of the composite decreased marginally compared to the as-received aluminum. As the dispersed particles pin dislocations, the strain-hardening rate of the composite was considerably increased and the same was seen in the Kocks-Mecking plot. The TiO{sub 2} particles are mechanically activated due to their fracture during FSP, hence leading to reaction with the matrix. The particle refinement and dispersion lead to a homogeneous matrix with higher strength.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Computational fluid dynamics modeling and analysis of silica nanoparticle synthesis in a flame spray pyrolysis reactor

Flame Spray Pyrolysis (FSP) is a method for large-scale production of nanoparticles and nanoscale powders employed in a wide range of industrial applications. Particle size and morphology are complex functions of the physicochemical phenomena occurring in the FSP reactor. An extensive study of FSP-related phenomena can be utilized to develop effective strategies for achieving desired particle size/morphology and scaling up the overall yield of an FSP system. In this work, a computational fluid dynamics (CFD) model of an FSP reactor is developed to simulate the coupling of key phenomena involved in the particle synthesis process: liquid spray breakup and evaporation, mixing, combustion, and particle formation/growth of silica nanoparticles. Herein, the particle sizes and their distributions from the CFD simulations are validated against experimental data. Subsequently, the simulations are utilized to investigate the impact of process parameters on the resultant flame dynamics and particle growth. Firstly, the CFD results show that the particle sizes are strongly correlated with the precursor concentration in the solvent. At lower precursor concentrations, the spread of the distribution is relatively insensitive to the value of the concentration. At higher concentrations, the spread is higher as the collision probability between particles is higher. Secondly, increasing the pilot flow rate increases the length of the pilot flames impacting the local ignition location of the spray flame. Lastly, it is shown that the dispersion gas flow rate strongly influences the spray flame shape. This shape can be used for control of particle growth as it helps determine the regions of high temperature and the residence time of the particles in the high temperature region enabling the design and process optimization of the FSP reactor.

42 ENGINEERING↗
DOE OSTI2018

Fabrication of Al-Zn solid solution via friction stir processing

Highlights: • Thermomechanical nature of FSP was utilized for mechanical alloying. • Zn particles dissolved in Al during FSP to form solid solution. • Second pass of FSP lead to homogenization and partial decomposition of the solid solution. • Processed alloy exhibited improved hardness over base and FSPed metal. • The process can be adopted for site specific property enhancement. - Abstract: The present study demonstrates that friction stir processing (FSP) can be used as a mechanical alloying tool to process solid solution. Zn was incorporated in commercially pure aluminium by multi-pass FSP leading to its dissolution and formation of supersaturated solid solution which was confirmed by X-ray diffraction and scanning electron microscopy. The hardness across the stir zone matched with the distribution of Zn and was significantly improved compared to the base metal. The supersaturated solid solution that formed in the first pass, partially decomposed during the second pass, leading to the formation of fine Al-Zn precipitates. Thermal stability of the microstructure against abnormal grain growth was also improved after the second pass due to the pinning effect of the grain boundary precipitates. FSP also caused grain refinement of the alloy yielding fine equiaxed grains in the range of 4–6 μm with a high fraction (> 67%) of high angle grain boundaries. Such microstructure is conducive for isotropic properties and the fact that the microstructure is stable against thermal cycles make the process suitable for selective alloying for location specific property enhancement.

36 MATERIALS SCIENCE↗