Engineering topics

Kesler, Michael [ORNL] (ORCID:0000000161423128)

Publications and source records attributed to Kesler, Michael [ORNL] (ORCID:0000000161423128).

3 records

DOE OSTI2026

Comparative Analysis of Austenitized Steel Microstructures Due to Induction and Conventional Heating in High Magnetic Field

While magnetic field-assisted processing shows promise in improving alloys’ mechanical properties, insufficient descriptions of heating methods hinder development of tailored processing pathways. This study investigates how induction and conventional heating affect microstructures of near-eutectoid Fe–C steel with and without 9 T magnetic field. Conventionally heated samples in field showed more austenite grain growth compared to inductively heated counterparts. Annealing twin frequency increased under field, with twin density increases not fully explained by larger grain sizes.

Hurley, Megan [University of Florida, Gainesville]↗

DOE OSTI2025

Simultaneously Improving Process Efficiency and Mechanical Properties in Aluminum Alloys with Applied Magnetic Fields

In the aluminum heat treatment sector, large resistive batch furnaces are used for many heat treatment processes and are generally always running, operating at approximately 20–30% efficiency. The primary avenue for energy savings lies in shortening heat treatment times, which can be 24+ hours for solutionizing (450–625 °C) and aging treatments (150–250 ℃), depending on the alloy and specification requirements. The application of high magnetic fields (<9 T) has shown to significantly reduce aluminum alloy heat treatment times, while achieving enhanced mechanical properties. Here, we explore the effects of thermomagnetic processing on the heat treatment response of a commercial aluminum alloy A390.1. Heat treatment times were reduced by >80%, while achieving ~10% improvement in microhardness, and these improvements persisted after longer thermal exposures simulating use. The microstructural evolution and resulting properties will be discussed.

Kesler, Michael [ORNL] (ORCID:0000000161423128)↗

DOE OSTI2025

Corrosion Resistance of an AlCeMg/Stainless-Steel Reactive Bond

A major issue for metal components in many industries is corrosion as it can substantially reduce their lifetime. This issue is especially problematic for materials used in heat exchanger applications. Al–Ce–Mg alloys, which exhibit corrosion resistance and can reactively bond with other metals, may be a viable solution to this problem. This investigation studied the corrosion behavior of Al–2Ce–6Mg (atomic percent)/stainless-steel (SS) reactive bond interfaces after full immersion in nitric, sulfuric, formic, and mixed acid for 267 h. This particular Al–Ce–Mg alloy was chosen due to its good castability. The results of scanning electron microscope characterization showed that reactive bond formations repeatedly occurred throughout the length of the casting in the as-cut samples and that these formations maintained a secure bonding between the alloy and the stainless-steel tubes. Transmission electron microscopy results showed that there was a clear compositional and microstructural transition across the reactive bond. The results of the immersion tests indicated that the nitric, sulfuric, and the mixed acid did not have an observably negative effect on the reactive bond structure. As for the sample exposed to formic acid only, noticable changes were seen in both the microstructural appearance and the elemental profile across the bond, suggesting that oxide formation occurred.

Brechtl, Jamieson [ORNL] (ORCID:0000000217394283)↗