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DOE OSTI2024

Peak microhardness recovery via T6 heat treatment with extremely soft annealed Al7075 feedstock in additive friction stir deposition

With standard T6 heat treatments, precipitate-hardened alloys such as Al7075 and Al6061 fabricated using Additive Friction Stir Deposition (AFSD) method restore to noticeablely different peak mechanical properties. Previous research observed similar results but did not provide a viable solution. This study proposes a new processing strategy, namely enhanced plastic deformation by subjecting the Al7075 feedstock to annealed softening treatments. Specifically, by annealing the standard T651-Al7075 feedstock and deposition substrate (179 HV), their Microhardness were first degraded to its lowest state (80 HV), which is called a Soft-to-Soft system. For the Soft-to-Soft system subjected to AFSD, after undergoing appropriate T6 heat treatment, the microhardness of the AFSD 7075 alloy was restored to its peak value (183.1 ± 1.8 HV). The results indicate that this softening strategy can effectively reduce the non-strengthening phase in the AFSD matrix, thereby increasing the strengthening phase (η′ phase). This addresses the issue of traditional AFSD-prepared aluminum alloys being unable to achieve peak performance through T6 heat treatment.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Microstructurally resolved electrochemical evolution of mechanical- and irradiation-induced damage in nuclear alloys

Abstract There is a need for high-throughput, scale-relevant, and direct electrochemical analysis to understand the corrosion behavior and sensitivity of nuclear materials that are exposed to extreme (high pressure, temperature, and radiation exposure) environments. We demonstrate the multi-scale, multi-modal application of scanning electrochemical cell microscopy (SECCM) to electrochemically profile corrosion alterations in nuclear alloys in a microstructurally resolved manner. Particularly, we identify that both mechanically deformed and irradiated microstructures show reduced charge-transfer resistance that leads to accelerated oxidation. We highlight that the effects of mechanical deformation and irradiation are synergistic, and may in fact, superimpose each other, with implications including general-, galvanic-, and/or irradiation-activated stress-corrosion cracking. Taken together, we highlight the ability of non-destructive, electrochemical interrogations to ascertain how microstructural alterations result in changes in the corrosion tendency of a nuclear alloy: knowledge which has implications to rank, qualify and examine alloys for use in nuclear construction applications.

Chen, Xin↗

DOE OSTI2026

Creep in multi-principal element materials –– A review

The ongoing push towards enhanced energy efficiency and reduced emissions has necessitated the creation of materials with superior performance, especially under extreme conditions. Modern industries, such as aerospace, energy production, and nuclear power, rely heavily on materials that can withstand elevated temperatures without compromising structural integrity. At these heightened temperatures, materials, even when subjected to mechanical stresses well below their yield strength, may experience slow deformation leading to eventual rupture — a phenomenon known as creep. With the expansive design space that comes with the high entropy concept and their reported excellent high temperature strength, multi-principal element materials (MPEMs) have attracted interest in the scientific community for high-temperature applications. Here, this review offers a comprehensive examination of existing studies on creep in MPEMs, which includes multi-principal element−alloys, −bulk metallic glasses, −ceramics, and −superalloys, comparing published findings on MPEMs with pure elements, traditional alloys, bulk metallic glasses, and superalloys. The sub-topics covered include a comparison among different creep-testing methods, creep mechanisms, creep exponents, creep strain rates, activation volume, and creep-activation energy. Modeling efforts for predicting creep behavior of MPEMs are also reviewed. Methods for improving creep resistance by performing heat treatments and/or modifying microstructures are discussed. Overall, the current state of MPEMs has not yet surpassed the creep performance of commercial alloys. Finally, directions for future efforts are suggested, such as experimenting in various controlled environments, expanding the number of compositions tested, exploring advanced manufacturing techniques, and using machine-learning to predict creep properties based on compositions and microstructures.

36 MATERIALS SCIENCE↗

NASA NTRS2008

Embossed Teflon AF Laminate Membrane Microfluidic Diaphragm Valves

A microfluidic system has been designed to survive spaceflight and to function autonomously on the Martian surface. It manipulates microscopic quantities of liquid water and performs chemical analyses on these samples to assay for the presence of molecules associated with past or present living processes. This technology lies at the core of the Urey Instrument, which is scheduled for inclusion on the Pasteur Payload of the ESA ExoMars rover mission in 2013. Fabrication processes have been developed to make the microfabricated Teflon-AF microfluidic diaphragm pumps capable of surviving extreme temperature excursions before and after exposure to liquid water. Two glass wafers are etched with features and a continuous Teflon membrane is sandwiched between them (see figure). Single valves are constructed using this geometry. The microfabricated devices are then post processed by heating the assembled device while applying pneumatic pressure to force the Teflon diaphragm against the valve seat while it is softened. After cooling the device, the embossed membrane retains this new shape. This solves previous problems with bubble introduction into the fluid flow where deformations of the membrane at the valve seat occurred during device bonding at elevated temperatures (100-150 C). The use of laminated membranes containing commercial Teflon AF 2400 sheet sandwiched between spun Teflon AF 1600 layers performed best, and were less gas permeable than Teflon AF 1600 membranes on their own. Spinning Teflon AF 1600 solution (6 percent in FLOURINERT(Registered TradeMark) FC40 solvent, 3M Company) at 500 rpm for 1.5 seconds, followed by 1,000 rpm for 3 seconds onto Borofloat glass wafers, results in a 10-micron-thick film of extremely smooth Teflon AF. This spinning process is repeated several times on flat, blank, glass wafers in order to gradually build a thick, smooth membrane. After running this process at least five times, the wafer and Teflon coating are heated under vacuum at 220 C for one hour in order to drive off any residual solvent present in the composite film. After this, a second blank, glass wafer is brought down from above and the stack is held under vacuum at 3 atm mechanical pressure for ten 10 hours.

Willis, Peter↗

DOE OSTI2023

Interface microstructure effects on dynamic failure behavior of layered Cu/Ta microstructures

Abstract Structural metallic materials with interfaces of immiscible materials provide opportunities to design and tailor the microstructures for desired mechanical behavior. Metallic microstructures with plasticity contributors of the FCC and BCC phases show significant promise for damage-tolerant applications due to their enhanced strengths and thermal stability. A fundamental understanding of the dynamic failure behavior is needed to design and tailor these microstructures with desired mechanical responses under extreme environments. This study uses molecular dynamics (MD) simulations to characterize plasticity contributors for various interface microstructures and the damage evolution behavior of FCC/BCC laminate microstructures. This study uses six model Cu/Ta interface systems with different orientation relationships that are as- created, and pre-deformed to understand the modifications in the plasticity contributions and the void nucleation/evolution behavior. The results suggest that pre-existing misfit dislocations and loading orientations (perpendicular to and parallel to the interface) affect the activation of primary and secondary slip systems. The dynamic strengths are observed to correlate with the energy of the interfaces, with the strengths being highest for low-energy interfaces and lowest for high-energy interfaces. However, the presence of pre-deformation of these interface microstructures affects not only the dynamic strength of the microstructures but also the correlation with interface energy.

42 ENGINEERING↗

NASA NTRS1986

An imaging extreme ultraviolet spectrometer for astrophysical investigations in space

A high-efficiency, extreme ultraviolet (EUV) imaging spectrometer has been constructed and tested. The spectrometer employs a concave toroidal grating illuminated at normal incidence in a Rowland circle mounting and has only one reflecting surface. The toroidal grating has been fabricated by a new technique employing an elastically deformable submaster grating which is replicated in a spherical form and then mechanically distorted to produce the desired aspect ratio of the toroidal surface for stigmatic imaging over the selected wavelength range. The fixed toroidal grating used in the spectrometer is then replicated from this surface. Photographic tests and initial photoelectric tests with a two-dimensional, pulse-counting detector system have verified the image quality of the toroidal grating at wavelengths near 600 A. The basic designs of two instruments employing the spectrometer for astrophysical investigations in space are described, namely, a high-resolution EUV spectroheliometer for studies of the solar chromosphere, transition region, and corona; and an EUV spectroscopic telescope for studies of nonsolar objects.

Huber, M. C. E.↗

NASA NTRS1987

Deformation of the core-mantle boundary induced by spherical-shell, compressible convection

Single-mode, mean-field equations, for spherical-shell convection are derived, with variable viscosity and compressibility included. Core-mantle boundary (CMB) topography produced by whole mantle convection is computed for various rheologies and different thermal boundary conditions at CMB. Results for long-wavelength undulations show the extreme sensitivity of these signatures to rheological and equation of state parameters. In order to obtain excess ellipticity of about 1 km, the activation energy and volume in the lower mantle should be low, and the temperatures at CMB should be around 4500 K, in accord with recent experimental findings.

Zhang, Shuxia↗

DOE OSTI2021

Characterization of ductile phase toughening mechanisms in a hot-rolled tungsten heavy alloy

Not Available

Haag, IV, James V. (ORCID:0000000252899930)↗

NASA NTRS1997

Optimization of a Parallel Ocean General Circulation Model

One of the principal roles of the ocean in the global heat balance is storage of heat, which moderates seasonal extremes and leads to the contrast between ocean and continent temperatures.

3-dimensional ocean general circulation models (OG↗

NASA NTRS2007

Translator for Optimizing Fluid-Handling Components

A software interface has been devised to facilitate optimization of the shapes of valves, elbows, fittings, and other components used to handle fluids under extreme conditions. This software interface translates data files generated by PLOT3D (a NASA grid-based plotting-and- data-display program) and by computational fluid dynamics (CFD) software into a format in which the files can be read by Sculptor, which is a shape-deformation- and-optimization program. Sculptor enables the user to interactively, smoothly, and arbitrarily deform the surfaces and volumes in two- and three-dimensional CFD models. Sculptor also includes design-optimization algorithms that can be used in conjunction with the arbitrary-shape-deformation components to perform automatic shape optimization. In the optimization process, the output of the CFD software is used as feedback while the optimizer strives to satisfy design criteria that could include, for example, improved values of pressure loss, velocity, flow quality, mass flow, etc.

Landon, Mark↗

NASA NTRS1986

Application of multiple objective optimization techniques to finite element model tuning

This report examines tuning a finite element model using vector optimization techniques. Structural models using finite element theory often need to be adjusted so they can accurately simulate the real structure. The goal is to tune the model such that it will reproduce data derived from structural tests. First, the performance indices are extremized using multiple objective optimization theory, producing a set of possible solutions. Next, the solutions are rank ordered according to a decision maker's preferences to select the best answer. The tuning process was applied to a T-38 horizontal stabilizer. Numerous weighted solutions contained a best static deformation model, a best frequency model and three intermediate combinations of these two models. This automated procedure proved to be a versatile method capable of producing solutions for many types of tuning problems.

Devore, Charles R.↗

NASA NTRS2002

Biomolecular Effects of Cold Plasma Exposure

The effects of cold plasma exposure on Deinococcus radiodurans, plasmid DNA and model proteins were assessed using microbiological, spectrometric and biochemical techniques. Exposure of D. radiodurans, an extremely radiation resistant microbe, to O2 plasma (less than or equal to 25 W, approx. 45 mTorr, 90 min) yielded a approx. 99.999 % sterilization and the sterilization rate was increased approx. 10-fold at 100 W and 500 mTorr. AFM images shows that the exposed cells are significantly deformed and possess 50-70 nm concavities. IR analysis indicates the chemical degradation of lipids, proteins and carotenoids of the cell wall and membrane. Intracellular damage was indicated by major absorbance loss at 1245, 1651 and 1538/cm corresponding to degradation of DNA and proteins, respectively. Biochemical experiments demonstrate that plasmas induce strand scissions and crosslinking of plasmid DNA, and reduction of enzyme activity; the degradation is power dependent with total sample loss occurring in 60 s at 200 W and 500 mTorr. Emission spectroscopy shows that D. radiodurans is volatilized into CO2, CO, N2 and H2O confirming the removal of biological matter from contaminated surfaces. The O2 plasma impacts several cellular components predominantly through chemical degradation by atomic oxygen. A CO2, plasma, however, was not effective at degrading D. radiodurans, revealing the importance of plasma composition, which has implications for planetary protection and the contamination of Mars.

Mogul, Rakesh↗

NASA NTRS2004

A Low Mass Translation Mechanism for Planetary FTIR Spectrometry using an Ultrasonic Piezo Linear Motor

One of the key components of a Fourier Transform Infrared Spectrometer (FTIR) is the linear translation stage used to vary the optical path length between the two arms of the interferometer. This translation mechanism must produce extremely constant velocity motion across its entire range of travel to allow the instrument to attain high signal-to-noise ratio and spectral resolving power. A new spectrometer is being developed at the Jet Propulsion Laboratory under NASA s Planetary Instrument Definition and Development Program (PIDDP). The goal of this project is to build upon existing spaceborne FTIR spectrometer technology to produce a new instrument prototype that has drastically superior spectral resolution and substantially lower mass, making it feasible for planetary exploration. In order to achieve these goals, Alliance Spacesystems, Inc. (ASI) has developed a linear translation mechanism using a novel ultrasonic piezo linear motor in conjunction with a fully kinematic, fault tolerant linear rail system. The piezo motor provides extremely smooth motion, is inherently redundant, and is capable of producing unlimited travel. The kinematic rail uses spherical Vespel(R). rollers and bushings, which eliminates the need for wet lubrication, while providing a fault tolerant platform for smooth linear motion that will not bind under misalignment or structural deformation. This system can produce velocities from 10 - 100 mm/s with less than 1% velocity error over the entire 100-mm length of travel for a total mechanism mass of less than 850 grams. This system has performed over half a million strokes under vacuum without excessive wear or degradation in performance. This paper covers the design, development, and testing of this linear translation mechanism as part of the Planetary Atmosphere Occultation Spectrometer (PAOS) instrument prototype development program.

Heverly, Matthew↗

DOE OSTI2026

Modeling frequency instability in high-quality resonant experiments

Modern resonant sensing tools can achieve increasingly high quality factors, which correspond to extremely narrow linewidths. In such systems, time variation of the resonator’s natural frequency can potentially impact its ability to accumulate power and its resulting sensitivity. One such example is the Dark SRF experiment, which utilizes superconducting radio frequency (SRF) cavities with quality factors of Q ∼ 10 10 . Microscopic deformations of the cavity lead to stochastic jittering of its resonant frequency with amplitude 20 times its linewidth. Naively, one may expect this to lead to a large suppression in accumulated power. In this work, we study in detail the effects of frequency instability on high-quality resonant systems, utilizing the Dark SRF experiment as a case study. We show that the timescale of jittering is crucial to determining its effect on power accumulation. Namely, when the resonant frequency varies sufficiently quickly, the system accumulates power as if there were no jittering at all. This implies that the sensitivity of a jittering resonator is comparable to that of a stable resonator. In the case of Dark SRF, we find that jittering only induces a ∼ 10 % loss in power. Our results allow the dark-photon exclusion bound from Dark SRF’s pathfinder run to be refined, leading to a constraint that is an order of magnitude stronger than previously reported (corresponding to a signal-to-noise ratio that is four orders of magnitude larger). This result represents the world-leading constraint on dark photons over a wide range of masses below 6 μ eV and translates to the best laboratory-based limits on the photon mass m γ < 2.9 × 10 - 48 g .

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

NASA NTRS2015

Modeling the Effects of Spaceflight on the Posterior Eye in VIIP

Purpose: Visual Impairment and Intracranial Pressure (VIIP) syndrome is a new and significant health concern for long-duration space missions. Its etiology is unknown, but is thought to involve elevated intracranial pressure (ICP)that induces connective tissue changes and remodeling in the posterior eye (Alexander et al. 2012). Here we study the acute biomechanical response of the lamina cribrosa (LC) and optic nerve to elevations in ICP utilizing finite element (FE) modeling. Methods: Using the geometry of the posterior eye from previous axisymmetric FE models (Sigal et al. 2004), we added an elongated optic nerve and optic nerve sheath, including the pia and dura. Tissues were modeled as linear elastic solids. Intraocular pressure and central retinal vessel pressures were set at 15 mmHg and 55 mmHg, respectively. ICP varied from 0 mmHg (suitable for standing on earth) to 30 mmHg (representing severe intracranial hypertension, thought to occur in space flight). We focused on strains and deformations in the LC and optic nerve (within 1 mm of the LC) since we hypothesize that they may contribute to vision loss in VIIP. Results: Elevating ICP from 0 to 30 mmHg significantly altered the strain distributions in both the LC and optic nerve (Figure), notably leading to more extreme strain values in both tension and compression. Specifically, the extreme (95th percentile) tensile strains in the LC and optic nerve increased by 2.7- and 3.8-fold, respectively. Similarly, elevation of ICP led to a 2.5- and 3.3-fold increase in extreme (5th percentile) compressive strains in the LC and optic nerve, respectively. Conclusions: The elevated ICP thought to occur during spaceflight leads to large acute changes in the biomechanical environment of the LC and optic nerve, and we hypothesize that such changes can activate mechanosensitive cells and invoke tissue remodeling. These simulations provide a foundation for more comprehensive studies of microgravity effects on human vision, e.g. to guide biological studies in which cells and tissues are mechanically loaded in a ranger elevant for microgravity conditions.

gravitational physiology↗

NASA NTRS1973

The San Andreas fault experiment

A plan was developed during 1971 to determine gross tectonic plate motions along the San Andreas Fault System in California. Knowledge of the gross motion along the total fault system is an essential component in the construction of realistic deformation models of fault regions. Such mathematical models will be used in the future for studies which will eventually lead to prediction of major earthquakes. The main purpose of the experiment described is the determination of the relative velocity of the North American and the Pacific Plates. This motion being so extremely small, cannot be measured directly but can be deduced from distance measurements between points on opposite sites of the plate boundary taken over a number of years.

Smith, D. E.↗

NASA NTRS1985

The role of silver in self-lubricating coatings for use at extreme temperatures

The advantages and disadvantages of elemental silver as a tribological material are discussed. It is demonstrated that the relatively high melting point of 961 deg C, softness, marked plasticity, and thermochemical stability of silver combine to make this metal useful in thin film solid lubricant coatings over a wide temperature range. Disadvantages of silver during sliding, except when used as a thin film, are shown to be gross ploughing due to plastic deformation under load with associated high friction and excessive transfer to counterface surfaces. This transfer generates an irregular surface topography with consequent undesirable changes in bearing clearance distribution. Research to overcome these disadvantages of element silver is described. A comparison is made of the tribological behavior of pure silver with that of silver formulated with other metals and high-temperature solid lubricants. The composite materials are prepared by co-depositing the powdered components with an airbrush followed by furnace heat treatment or by plasma-spraying. Composite coatings were formulated which are shown to be self-lubricating over repeated, temperature cycles from low temperature to about 900 deg C.

Sliney, H. E.↗

NASA NTRS1986

The use of silver in self-lubricating coatings for extreme temperatures

Sliney, H. E.↗