Acoustic-energy shaping of meltable metals
Containerless shaping technique is applicable to machining metals technology. Process improves quality of melted metals by reducing introduction of impurities from container walls or floor.
Elleman, D. D.↗
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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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Nanomechanical Characterization of Additive Manufactured GRCop-42 Alloy Developed by Directed Energy Deposition Methods
Propulsion applications such as combustion chambers and nozzles for liquid rocket engines require the use of unique materials with superior mechanical and thermal properties. GRCop-42(Cu-4 wt.% Cr-2 wt.% Nb) is one such candidate material developed by NASA and is now being manufactured using additive manufacturing (AM) techniques. AM offers a unique processing environment different from traditional metal fabrication processes. This study characterized the mechanical and structural properties of as-deposited and heat-treated GRCop-42manufactured with Blown Powder Directed Energy Deposition (BPD)based on preliminary testing. The materials were characterized using several techniques including surface profiling by laser microscopy, mechanical stiffness by instrumented indentation, crystal structure, residual stress measurements using XRD and residual XRD, and chemical composition and microstructural evaluation using SEM with EBSD. The results of the study are compared using the BPD techniques for samples in the as-deposited and heat-treated conditions.
GRCop-42↗
Flash Thermal Diffusivity Measurements and Inspection of Additively Manufactured Ti-6Al-4V Specimens with Varying Process Parameters
Flash thermal diffusivity measurements were obtained on additively manufactured Ti-6Al-4V disk shaped specimens with various process parameters. For additively manufactured metal parts, processing parameters such as laser power and scanning speed are critical to ensure the desired microstructure. For this study, the laser powder bed fusion process parameters were changed at various angular sections on a 21 mm diameter and 3.0 mm thick disk. The measurement of thermal diffusivity was performed by fitting a 1-dimensional thermal model to the data pixel by pixel to produce an inspection image. The image revealed the detection of defects such as lack of fusion porosity and areas of aggregated porosity. The thermal diffusivity imagery was compared to immersion scan ultrasonic and X-ray computed tomography (CT) measurements for validation. Based on these results, additional samples were investigated using a single side thermal inspection technique to detect lack of fusion porosity and near surface voids.
thermal nondestructive evaluation↗
Flash Thermal Diffusivity Measurements and Inspection of Additively Manufactured Ti-6Al-4V Specimens with Varying Process Parameters
Flash thermal diffusivity measurements were obtained on additively manufactured Ti-6Al-4V disk shaped specimens with various process parameters. For additively manufactured metal parts, processing parameters such as laser power and scanning speed are critical to ensure the desired microstructure. For this study, the laser powder bed fusion process parameters were changed at various angular sections on a 21 mm diameter and 3.0 mm thick disk. The measurement of thermal diffusivity was performed by fitting a 1-dimensional thermal model to the data pixel by pixel to produce an inspection image. The image revealed the detection of defects such as lack of fusion porosity and areas of aggregated porosity. The thermal diffusivity imagery was compared to immersion scan ultrasonic and X-ray computed tomography (CT) measurements for validation. Based on these results, additional samples were investigated using a single side thermal inspection technique to detect lack of fusion porosity and near surface voids.
thermal nondestructive evaluation↗
The role of rapid solidification processing in the fabrication of fiber reinforced metal matrix composites
Advanced composite processing techniques for fiber reinforced metal matrix composites require the flexibility to meet several widespread objectives. The development of uniquely desired matrix microstructures and uniformly arrayed fiber spacing with sufficient bonding between fiber and matrix to transmit load between them without degradation to the fiber or matrix are the minimum requirements necessary of any fabrication process. For most applications these criteria can be met by fabricating composite monotapes which are then consolidated into composite panels or more complicated components such as fiber reinforced turbine blades. Regardless of the end component, composite monotapes are the building blocks from which near net shape composite structures can be formed. The most common methods for forming composite monotapes are the powder cloth, foil/fiber, plasma spray, and arc spray processes. These practices, however, employ rapid solidification techniques in processing of the composite matrix phase. Consequently, rapid solidification processes play a vital and yet generally overlooked role in composite fabrication. The future potential of rapid solidification processing is discussed.
Locci, Ivan E.↗
System and method for light assisted friction stir processing and welding of metallic and non-metallic materials
An apparatus for use in a friction stir operation, such as friction stir welding (FSW) or friction stir processing (FSP). The apparatus may have a rotating tool adapted to be plunged into a material, where the material is susceptible to being softened by heating. The rotating tool may further be adapted to be advanced along a surface of the material. An optical energy generating subsystem may be used to heat a portion of the material using optical energy as the tool is advanced along the material.
42 ENGINEERING↗
Influence of Metal Ion Complexation on the Radiolytic Longevity of Butyramide Extractants under Direct Dissolution Process Conditions
The direct dissolution of voloxidized used nuclear fuel (UNF) into an organic solution–comprised of diluent and specialized extractants–poses a promising alternative to the traditional liquid–liquid solvent extraction approach to reprocessing UNF. However, moving to direct dissolution removes the presence of a concentrated nitric acid aqueous phase, which has been shown to significantly influence the radiolytic longevity of extractants in conventional extraction flowsheets. Given the limited knowledge of radiation effects under direct dissolution conditions, here we present a time-resolved and dose-accumulation study on the impact of direct dissolution conditions on the radiolytic longevity of two candidate butyramide extractants, N,N-di(2-ethylhexyl) butyramide (DEHBA) and N,N-di(2-ethylhexyl)isobutyramide (DEHiBA), in pre-equilibrated n-dodecane solvent in the presence and absence of process-relevant metal ions, specifically, uranium and rhenium. Loss G(DEHBA) and G(DEHiBA) values were found to be comparable to each other, with an average of 0.37 ± 0.02 μmol J –1 , and to previous data from the γ irradiation of DEHBA and DEHiBA under conventional solvent extraction conditions. Rhenium, and by extension technetium, extraction had a modest decrease (~10%) in the overall radiolytic stability of DEHiBA only, despite >2× observed increases in chemical kinetic reactivity of the corresponding complexes with the n-dodecane radical cation. Uranium loading, on the other hand, significantly improved the lifetime of both ligands (>30%) under γ irradiation, with a greater stabilization observed for DEHBA over DEHiBA. The observed radioprotective effect afforded by uranium loading is fortuitous for the longevity of direct dissolution solvent.
38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
Elaboration of Metallic Materials by SPS: Processing, Microstructures, Properties, and Shaping
After a few decades of increasing interest, spark plasma sintering (SPS) has now become a mature powder metallurgy technique, which allows assessing its performances toward fabricating enhanced materials. Here, the case of metals and alloys will be presented. The main advantage of SPS lies in its rapid heating capability enabled by the application of high intensity electric currents to a metallic powder. This presents numerous advantages balanced by some limitations that will be addressed in this review. The first section will be devoted to sintering issues, with an emphasis on the effect of the electric current on the densification mechanisms. Then, typical as-SPS microstructures and properties will be presented. In some cases, they will be compared with that of materials processed by conventional techniques. As such, examples of nanostructured materials, intermetallics, metallic glasses, and high entropy alloys, will be presented. Finally, the implementation of SPS as a technique to manufacture complex, near-net shape industrial parts will be discussed.
36 MATERIALS SCIENCE↗
Particle size effects in metallic microparticle impact-bonding
In cold spray processing of metals, the critical velocity for particle bonding is dependent on both intrinsic material properties, such as density and (spall) strength, and extrinsic process parameters, such as the powder particle size. Here, we specifically isolate and investigate particle size effects on the critical velocity for bonding through laser- induced single particle impact experiments and finite element simulations. We also present a predictive framework to correlate particle size and critical velocity. We show that an increase in particle size leads to an increase in the temperature of the jet formed at the interface of the particle and the substrate. This increased temperature locally decreases the spall strength of the material which, in turn, decreases the critical velocity for larger particles.
36 MATERIALS SCIENCE↗
LLNL Semiannual Wastewater Point Source Monitoring Report (July 2020)
In accordance with the Code of Federal Regulations, Title 40, Part 403.12(e), Lawrence Livermore National Laboratory (LLNL) submits a semiannual monitoring report regarding federally regulated wastewater generating processes (categorical processes) that discharge wastewater to the sanitary sewer system. Attachments A-2 and A-3 of the 2019-2020 Wastewater Discharge Permit #1250 granted to LLNL by the City of Livermore Water Resources Division (WRD) also mandate submission of this report. The LLNL Livermore Site is required to monitor identified electrical and electronic components processes (40 CFR Part 469) and metal finishing processes (40 CFR Part 433) semiannually and to submit monitoring reports in January and July of each year. Under authority delegated to enforce compliance with these regulations, the WRD reviews this report. This report provides information on the significant metal-finishing operations and electrical and electronic component operations located at the Livermore Site during the period from December 1, 2019 through May 31, 2020 and includes descriptions of the LLNL regulated (categorical) processes that discharge to the sanitary sewer. Attachments A-2 and A-3 of the 2019-2020 Wastewater Discharge Permit #1250 provide the list of categorical processes and the required self-monitoring program for point-source discharges at LLNL. The monitoring data collected for this report documents compliance with all federal and local pretreatment limits. Compliance certification accompanies this report, as required by federal regulations.
54 ENVIRONMENTAL SCIENCES↗
Diffusion of Siderophile Elements in Fe Metal: Application to Zoned Metal Grains in Chondrites
The distribution of highly siderophile elements (HSE) in planetary materials is controlled mainly by metal. Diffusion processes can control the distribution or re-distribution of these elements within metals, yet there is little systematic or appropriate diffusion data that can be used to interpret HSE concentrations in such metals. Because our understanding of isotope chronometry, redox processes, kamacite/taenite-based cooling rates, and metal grain zoning would be enhanced with diffusion data, we have measured diffusion coefficients for Ni, Co, Ga, Ge, Ru, Pd, Ir and Au in Fe metal from 1200 to 1400 C and 1 bar and 10 kbar. These new data on refractory and volatile siderophile elements are used to evaluate the role of diffusional processes in controlling zoning patterns in metal-rich chondrites.
Righter, K.↗
The efficacy of Lewis affinity scale metrics to represent solvent interactions with reagent salts in all-inorganic metal halide perovskite solutions
Solvents employed in the solution processing of metal halide perovskites are known to play a key role in defining the morphology and properties of the resulting thin film, and thus the performance of perovskite solar cell devices. Accurate metrics are needed that are capable of differentiating among candidates, finding solvents that adequately solubilize the various precursor species in solution and facilitate the nucleation and growth of these materials. Existing metrics such as the unsaturated Mayer bond order (UMBO) and the Gutmann donor number (DN) have been tested for lead iodide perovskite systems; but there has yet to be a comprehensive study on their transferability to lead-free perovskite solutions. Here, we use ab initio methods (density functional theory) and regression analysis tools to study the usefulness of DN and BF 3 affinity scales in this regard. We compared the relative effectiveness of these scales to describe interactions between solvents and BXn perovskite salts of lead (Pb 2+ ), tin (Sn 2+ and Sn 4+ ), germanium (Ge 2+ ), bismuth (Bi 3+ ), and antimony (Sb 3+ and Sb 5+ ). The DN proved to be a better representation than the BF 3 of such interactions, reflecting the closer similarity of these species to the “parent” SbCl 5 Lewis acid than to BF 3 . In addition, we have uncovered the usefulness of the lithium cation affinity metric (LCA) to describe the strength of interactions between solvents and A-site cations (e.g. Na + , K + , Rb + and Cs + ) in all-inorganic metal halide perovskite solutions. We find that the coordination strengths of solvents towards species in all-inorganic metal halide perovskite solutions are best described by two different metrics with distinct modes of action: DN differentiates among BX n salt complexes, and LCA among A-site cation species. This revelation can help guide the choice of solvent to optimize processing conditions. It also emphasizes the importance of selecting solvents whose DN and LCA optimize coordination to key Lewis acid species in all-inorganic perovskite solutions.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Bridging Transition Metal and Anion Redox Processes in Li-Rich Sulfide Cathodes
Li-ion batteries are essential for decarbonizing global transport and energy, but their scalability is constrained by limited supplies of critical cathode elements, such as Ni, Mn, Co, and P. To address this, we previously introduced high-energydensity Li-ion cathodes composed of Al, Fe, and S, which are elements already produced globally at industrial scale and batterygrade purity. These cathodes leverage sulfide anion redox, involving nonbonding S 3p states and localized distortions that form and break S−S bonds, enabling high capacity. Here, we expand this chemical space by incorporating Cu into cathodes Li 2.2d−z Cu z Al 0.2 Fe 0.6 S 2 (0 ≤ z ≤ 0.4), where highly covalent Cu−S interactions stabilize holes on Cu as Cu >1+ . This Cu redox extends charge compensation that was previously restricted to localized, electronically isolated S−S bonds. Cu also limits capacity, which we attribute to structural destabilization of the delithiated phase, despite the thermodynamic stability of Cu >1+ . By describing the effects of Cu on charge compensation and phase stability, we present a sulfide anion redox mechanism for next-generation multielectron redox Li-ion cathodes, where highly covalent transition metal states participate in otherwise electronically isolated redox processes involving anion nonbonding states.
Anions↗
Study of the adsorption of gases on metals by the Auger process
Gas adsorption-desorption apparatus using electron impact helium ion source and single crystal tungsten ribbon target
SINGLE CRYSTAL↗
Apollo-Soyuz pamphlet no. 8: Zero-g technology
The behavior of liquids in zero gravity environments is discussed with emphasis on foams, wetting, and wicks. A multipurpose electric furnace (MA-010) for the high temperature processing of metals and salts in zero-g is described. Experiments discussed include: monolectic and synthetic alloys (MA-041); multiple material melting point (MA-150); zero-g processing of metals (MA-070); surface tension induced convection (MA-041); halide eutectic growth; interface markings in crystals (MA-060); crystal growth from the vapor phase (MA-085); and photography of crystal growth (MA-028).
Page, L. W.↗
Modeling of Transport Processes in Liquid-Metal Fusion Blankets: Past, Present, and Future
The successful development of robust breeding blanket systems will strongly rely on computational tools for predicting the complex behavior of the electrically conducting liquid-metal (LM) breeder flowing in the complex-shaped blanket ducts in the presence of a strong plasma-confining magnetic field, volumetric heating, and tritium generation. Associated transport processes involve magnetohydrodynamic (MHD) flows, heat transfer, corrosion, and tritium transport. This paper is an overview of past and present efforts in the development, application, and verification and validation (V&V) of such computational tools. As a result of the ongoing campaign on V&V of computer codes for LM blankets, the international fusion community has identified several candidates that promise to become real blanket design and analysis tools in the near future. Among them are HIMAG, MHD-UCAS, COMSOL Multiphysics, ANSYS FLUENT, ANSYS CFX, and OpenFOAM. The progress, over the last decade, in the application of such codes in blanket studies is tremendous. This is illustrated with two examples for a dual-coolant lead-lithium (DCLL) blanket: (1) integrated computer modeling for the recently designed DCLL blanket in the United States and (2) application of the code MHD-UCAS to the analysis of PbLi flows and heat transfer in a generic DCLL blanket prototype at high Hartmann (Ha ~ 10 4 ) and Grashof numbers (Gr ~ 10 12 ). Here, this paper also presents an approach to the development of a new integrated computational tool called the virtual dual-coolant lead-lithium (VDCLL) blanket, which elaborates the existing U.S. MHD code HIMAG.
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
Deformation During Friction Stir Welding
Friction Stir Welding (FSW) is a solid state welding process that exhibits characteristics similar to traditional metal cutting processes. The plastic deformation that occurs during friction stir welding is due to the superposition of three flow fields: a primary rotation of a radially symmetric solid plug of metal surrounding the pin tool, a secondary uniform translation, and a tertiary ring vortex flow (smoke rings) surrounding the tool. If the metal sticks to the tool, the plug surface extends down into the metal from the outer edge of the tool shoulder, decreases in diameter like a funnel, and closes up beneath the pin. Since its invention, ten years have gone by and still very little is known about the physics of the friction stir welding process. In this experiment, an H13 steel weld tool (shoulder diameter, 0.797 in; pin diameter, 0.312 in; and pin length, 0.2506 in) was used to weld three 0.255 in thick plates. The deformation behavior during friction stir welding was investigated by metallographically preparing a plan view sections of the weldment and taking Vickers hardness test in the key-hole region.
Henry J. White↗
Processing and plating helical metallic coils
The results of research efforts to develop an optimized nickel cobalt coating suitable as a recording medium are outlined. The coating is to be used directly on a BeCu helical coil substrate of a helical coil NASA recorder. Specifically, efforts were made to: optimize the coating thickness; establish processes and techniques adaptable for the production of finalized plated helical coils; design and fabricate the equipment required for production and testing of the coils; and deliver finalized helical coils to NASA.
Source record↗