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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 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

A Review of Texture Evolution Mechanisms During Deformation by Rolling in Aluminum Alloys

The current understanding of texture evolution during deformation by rolling in aluminum alloys was summarized. This included understanding the evolution mechanisms and several key factors of initial texture, microstructure, alloy composition, deformation temperature, stress–strain condition, and rolling geometry. Related models on predicting texture evolution during rolling were also discussed. Finally, for this research field, the recommendations for controlling the formation of rolling textures were proposed.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Effect of Tempering and Rolling on Fatigue Crack Growth Behavior of Modified 9Cr-1Mo Steel

In the present work, fatigue crack growth (FCG) behavior of modified 9Cr-1Mo steel has been investigated near fatigue threshold and Paris regime at room temperature (RT) and 650 °C. The modified 9Cr-1Mo steel was subjected to normalizing at 1050 °C followed by tempering (650-750 °C) and warm rolling at 550 °C followed by tempering in order to improve its precipitation state and refine microstructure. The microstructural parameters such as grain size, block size, lath width and precipitate size were examined and correlated with FCG and tensile properties of investigated samples. The results showed that decreasing tempering temperature significantly reduces the fatigue threshold at RT while increases the yield strength at elevated temperature (i.e., 650 °C). Increase in fatigue threshold is found to increase with the increase in block size, whereas high density of fine precipitates contributed the high temperature strength. The FCG rate in Paris regime was less affected by heat treatment and rolling process at RT. However, rolled sample tested at 650 °C shows a decrease in FCG rate as compared to heat-treated samples. In terms of higher FCG resistance and yield strength, warm rolling followed by tempering at low temperature (i.e., 700 °C) can be considered optimum. For the numerical simulation of FCG behavior, extended finite element method (XFEM) along with Paris law has been implemented in ABAQUS using python script. The simulated FCG behavior is found in good agreement with the experimental results.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Processing of Ultrafine-Grained Steels by Warm Rolling and Annealing

Low-carbon microalloyed steel was subjected to warm rolling followed by rapid transformation annealing (RTA) at 800-850 °C and subcritical annealing (SCA) at 600 °C to develop ultrafine ferrite grain structures (UFFG) with grain size less than 3 μm. The present study investigated the influence of light (40%) and heavy (80%) warm rolling deformation (LWR and HWR) applied during the finishing pass of two-pass rolling schedules on the microstructural evolution after rolling and subsequent annealing treatments. RTA treatment of HWR sample at a lower intercritical temperature for an optimum duration (800 °C, 30 s) developed UFFG-martensite dual-phase structure that offered the best combination of strength (YS ~ 900 MPa and UTS ~ 1200 MPa) and ductility (25% elongation). The SCA treatment provided sufficient time to achieve a uniform distribution of carbide particles throughout the ferrite matrix. SCA treatment of HWR at 600 °C for 4 h developed UFFG-carbide structure achieving YS of 800 MPa with 20% ductility. The SCA of LWR resulted in coarser ferrite grain structures (grain size > 5 μm) having higher ductility (more than 30%) but lower strength (UTS of 400-550 MPa) as compared to RTA.

36 MATERIALS SCIENCE↗
DOE OSTI2016

3D analysis of macrosegregation in twin-roll cast AA3003 alloy

Twin-roll cast aluminium alloys have a high potential for industrial applications. However, one of the drawbacks of such materials is an inhomogeneous structure generated by macrosegregation, which appears under certain conditions in the center of sheets during solidification. Segregations in AA3003 alloy form as manganese, iron and silicon rich channels spread in the rolling direction. Their spatial distribution was successfully detected by X-ray computed tomography. Scanning electron microscopy was used for a detailed observation of microstructure, morphology and chemical analysis of the segregation. - Highlights: •Macrosegregations in twin-roll cast sheets stretch along the rolling direction. •X-ray computed tomography is an effective tool for visualization of the segregation. •The segregations copy the shape of grain boundaries.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Effect of Bi on the microstructure and mechanical properties of Sn-Zn alloys processed by rolling

Highlights: • Sn-Zn-Bi is proposed for the first time as the cladding in linear explosive device. • Bi can significantly refine the microstructure of Sn-Zn. • Bi can enhance both strength and ductility of Sn-Zn processed by rolling. • The 5 wt% Bi in Sn-3Zn leads to finest and most homogenous grains after rolling. - Abstract: Sn-Zn based alloys including Sn-3Zn, Sn-3Zn-1Bi, and Sn-3Zn-5Bi were prepared by casting and rolling, in efforts to assess their feasibility for the application as cladding materials in detonating and explosive cords. It was found that Bi significantly refined the solidification microstructure, changing the configuration of Sn-Zn eutectic from well-aligned Zn-rich precipitates/needles to misaligned Zn-rich flakes. During deformation, second phases like Zn-rich precipitates and Bi particles, and Bi solutes were effective in grain refinement since second phase particles provided more sites for nucleation and more obstacles to growth of new recrystallized grains. Tensile results revealed that Bi addition enhanced both strength and ductility of the rolled Sn-Zn-Bi alloys. The Sn-3Zn-5Bi alloy possessed superior strength and ductility (UTS: 84.4 MPa; Yield strength: 68.3 MPa; Elongation: 75.2%) due to its finest and most homogeneous equiaxed grains. Based on decent mechanical properties, the Sn-Zn-Bi alloys could be well qualified for the application as cladding materials.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Influence of finish rolling temperature on the microstructure and mechanical properties of Mg-8.5Al-0.5Zn-0.2Mn-0.15Ag alloy sheets

Highlights: • The microstructure is strongly depending on the finish rolling temperature. • Extensive shear zones parallel distributed across the sheets. • The formation process of shear zones in RH and RL are different. • Shear zones decide the mechanical anisotropy of the whole sheet. - Abstract: Mg-8.5Al-0.5Zn-0.2Mn-0.15Ag (wt%) magnesium sheets were produced with various final rolling temperatures, and their microstructures and mechanical properties were characterized. It was found that low final rolling temperature (LT) resulted in stronger heterogeneity, stronger basal texture and higher strength compared with the high final rolling temperature (HT). Considerable shear zones were observed within both the LT and HT sheets, even though their microstructures, formation mechanisms and mechanical properties were different. Preliminary analysis suggests that the shear zones exert great influence on the mechanical anisotropy of whole sheets.

36 MATERIALS SCIENCE↗
DOE OSTI2018

The effect of finish rolling temperature and tempering on the microstructure, mechanical properties and dislocation density of direct-quenched steel

Highlights: • The effect of thermomechanical treatment and tempering on direct-quenched steel has been studied. • Dislocation density of direct-quenched and tempered martensite is evaluated using both TEM and Williamson-Hall method. • Statistical analysis has been performed to study the effect of different factors on toughness of direct-quenched martensite. - Abstract: A unique batch tempering treatment for industrial scale direct-quenched steel coils has been studied using laboratory simulations. The tempering treatment was non-isothermal with slow heating to 570 °C and slow cooling to simulate the tempering of large steel coils. The paper presents the effect of finishing rolling temperature (FRT) relative to the non-recrystallization temperature (T{sub NR}) and the effect of long time tempering on the microstructure, dislocation density and mechanical properties of direct-quenched coiled strips. Conditioning austenite below the recrystallization stop temperature resulted in a finer effective grain size distribution, which correlated strongly with the impact toughness of the final product. Furthermore low finish rolling temperature resulted in partially ferritic microstructures while higher finishing rolling temperatures led to mixtures of bainite and martensite. Dislocation densities determined with TEM and XRD showed somewhat different trends regarding the effect of tempering: intra-lath dislocation density, as measured with TEM, showed a statistically significant drop in only one case, while XRD analysis indicated a drop in all cases. Furthermore, no significant correlation between finishing rolling temperature and dislocation density existed in XRD studies. The XRD results indicate that the decrease in dislocation density corresponds to about 100 MPa lower dislocation strengthening. However, precipitation hardening and potential internal micro stress relief compensates this as yield strength remains unchanged or even increases during tempering.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Microstructure, texture and mechanical properties of AA 1060 aluminum alloy processed by cryogenic accumulative roll bonding

Highlights: • The Al sheets were accumulative roll bonded to five cycles at cryogenic temperature. • The microstructure, texture and mechanical properties of ARB sheets were investigated. • The texture evolution at surface layer was quantified by mathematical formulae. • The strength of the β fiber at center layer was affected by the initial texture and the strain. - Abstract: AA 1060 aluminum alloy sheet was processed to five accumulative roll bonding (ARB) cycles at cryogenic temperature. The microstructure, texture and mechanical properties of the ARB processed sheets were investigated. The results show that the surface layer of the ARB processed sheets exhibits a significant r-cube shear texture. Initial cube orientation at the surface layer was gradually rotated to the r-cube orientation during the ARB process, leading to the increase in the strength of the r-cube shear texture with ARB cycles. The texture evolution at the surface layer was quantified in terms of a simple relation between the texture volume fractions and accumulated true strain. The strength of the β fiber rolling texture and the distribution of orientation intensities along the β fiber at the center layer were strongly affected by the initial texture. As the ARB cycles increased, the initial texture was changed from the cube texture to the r-cube texture, leading to a continuous increase in the strength of the β fiber rolling texture dominated by the C orientation. The yield and ultimate tensile strength of the ARB processed sheets increased markedly after the first ARB cycle and then increased slowly with increasing ARB cycles, while the elongation decreased accordingly.

36 MATERIALS SCIENCE↗
DOE OSTI2018

A superior combination of strength-ductility in CoCrFeNiMn high-entropy alloy induced by asymmetric rolling and subsequent annealing treatment

Highlights: • Asymmetric rolling was carried out to process bulk single face-centered-cubic (FCC) CoCrFeMnNi HEA. • A gradient microstructure and smaller average grain size was obtained through Asymmetric rolling and annealing process. • The processed alloys after Asymmetric rolling exhibits a superior combination of the high strength and good ductility. - Abstract: CoCrFeMnNi high-entropy alloy with a smaller average grain size and gradient microstructure was produced by asymmetric rolling (ASR) and subsequent annealing treatment, which gave rise to a superior combination of strength-ductility. High back stress, working hardening and geometrically necessary dislocations were detected in the gradient structure. The ultra-high strength of the CoCrFeMnNi high-entropy alloy was related to the fine grain and high back-stress, while the superior ductility was ascribed to the gradient structure and fine grain. ASR followed by annealing might be a novel strategy for designing high entropy alloys with high performance.

36 MATERIALS SCIENCE↗
DOE OSTI2019

New Functionality of Ionic Liquids as Lubricant Additives: Mitigating Rolling Contact Fatigue

Oil-soluble ionic liquids (ILs) have recently been demonstrated as effective lubricant additives of friction reduction and wear protection for sliding contacts. However, their functionality in mitigating rolling contact fatigue (RCF) is little known. Because of the distinct surface damage modes, different types of surface protective additives often are used in lubricants for sliding and rolling contacts. Therefore, the lubricating characteristics and mechanisms of ILs learned in sliding contacts from the earlier work may not be translatable to rolling contacts. This study explores the feasibility of using phosphonium-phosphate, ammonium-phosphate, and phosphonium-carboxylate ILs as candidate additives in rolling–sliding boundary lubrication, and results suggested that an IL could be either beneficial or detrimental on RCF depending on its chemistry. Particularly, the best-performing phosphonium-phosphate IL at 2% addition made a low-viscosity base oil significantly outperform a more viscous commercial gear oil in reducing the RCF surface damage and associated vibration noise. This IL generated a thicker, smoother, and more homogeneous tribofilm compared with commercial additives, which is likely responsible for the superior RCF protection. Results here suggest good potential for using appropriate IL additives to allow the use of low-viscosity gear and axle fluids for improved efficiency and durability.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Crystallographic texture of straight-rolled ?-uranium foils via neutron and X-ray diffraction

The texture of recrystallized straight-rolled ?-uranium foils, a component in prospective irradiation target designs for medical isotope production, has been measured by neutron diffraction, as well as X-ray diffraction using both Cu and Mo sources. Variations in the penetration depth of neutron and X-ray radiation allow for determination of both the bulk and surface textures. The bulk ?-uranium foil texture is similar to the warm straight-rolled plate texture, with the addition of a notable splitting of the (001) poles along the transverse direction. The surface texture of the foils is similar to the bulk, with an additional (001) texture component that is oriented between the rolling and normal directions. Differences between the surface and bulk textures are expected to arise from shear forces during the rolling process and the influence that distinct strain histories have on subsequent texture evolution during recrystallization.

36 MATERIALS SCIENCE↗
NASA NTRS2005

Free-to-Roll Investigation of the Pre-Production F/A-18E Powered Approach Wing Drop

A free-to-roll study of the low-speed lateral characteristics of the pre-production F/A-18E was conducted in the NASA Langley 12-Foot Low-Speed Tunnel. In developmental flight tests the F/A-18E unexpectedly experienced uncommanded lateral motions in the power approach configuration. The objective of this study was to determine the feasibility of using the free-to-roll technique for the detection of uncommanded lateral motions for the pre-production F/A-18E in the power approach configuration. The data revealed that this technique in conjunction with static data revealed insight into the cause of the lateral motions. The free-to-roll technique identified uncommanded lateral motions at the same angle-of-attack range as experienced in flight tests. The cause of the uncommanded lateral motions was unsteady asymmetric wing stall. The paper also shows that free-to-roll data or static force and moment data alone are not enough to accurately capture the potential for an aircraft to experience uncommanded lateral motion.

VERTICAL TAIL↗
NASA NTRS2016

Rolling Bearing Life Prediction, Theory, and Application

A tutorial is presented outlining the evolution, theory, and application of rolling-element bearing life prediction from that of A. Palmgren, 1924; W. Weibull, 1939; G. Lundberg and A. Palmgren, 1947 and 1952; E. Ioannides and T. Harris, 1985; and E. Zaretsky, 1987. Comparisons are made between these life models. The Ioannides-Harris model without a fatigue limit is identical to the Lundberg-Palmgren model. The Weibull model is similar to that of Zaretsky if the exponents are chosen to be identical. Both the load-life and Hertz stress-life relations of Weibull, Lundberg and Palmgren, and Ioannides and Harris reflect a strong dependence on the Weibull slope. The Zaretsky model decouples the dependence of the critical shear stress-life relation from the Weibull slope. This results in a nominal variation of the Hertz stress-life exponent. For 9th- and 8th-power Hertz stress-life exponents for ball and roller bearings, respectively, the Lundberg-Palmgren model best predicts life. However, for 12th- and 10th-power relations reflected by modern bearing steels, the Zaretsky model based on the Weibull equation is superior. Under the range of stresses examined, the use of a fatigue limit would suggest that (for most operating conditions under which a rolling-element bearing will operate) the bearing will not fail from classical rolling-element fatigue. Realistically, this is not the case. The use of a fatigue limit will significantly overpredict life over a range of normal operating Hertz stresses. (The use of ISO 281:2007 with a fatigue limit in these calculations would result in a bearing life approaching infinity.) Since the predicted lives of rolling-element bearings are high, the problem can become one of undersizing a bearing for a particular application. Rules had been developed to distinguish and compare predicted lives with those actually obtained. Based upon field and test results of 51 ball and roller bearing sets, 98 percent of these bearing sets had acceptable life results using the Lundberg- Palmgren equations with life adjustment factors to predict bearing life. That is, they had lives equal to or greater than that predicted. The Lundberg-Palmgren model was used to predict the life of a commercial turboprop gearbox. The life prediction was compared with the field lives of 64 gearboxes. From these results, the roller bearing lives exhibited a load-life exponent of 5.2, which correlated with the Zaretsky model. The use of the ANSI/ABMA and ISO standards load-life exponent of 10/3 to predict roller bearing life is not reflective of modern roller bearings and will underpredict bearing lives.

Life prediction↗
DOE OSTI2022

The Impact of Rolling at Temperature on Conductivity and Texture in Nanolamellar Cu/Nb Bimetallic Composites

We report warm rolling is used to identify whether reductions in dislocation content would provide a significant impact on conductivity in accumulatively roll-bonded Cu-Nb nanolaminates. In addition, the impact of temperature on mechanical properties and interfacial texture is also quantified. Although temperature has a strong effect on dislocation content and mechanical properties, it is shown that length scale and volume fraction are most critical to defining the conductivity of the nanolaminate. Rolling at temperature reduced the flow stress of the material while maintaining the interfacial and layer structure, indicating that warm rolling can increase the ability to process the nanolaminates without reducing conductivity.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Wear-Resistant Al/SiC-Gr Hybrid Metal Matrix Composite Fabricated by Multiple Annealing and Roll Bonding

The wear-resistant Al/SiC-Gr hybrid composite with a good combination of strength and ductility is fabricated by multiple annealing and roll bonding. The challenge is that graphite acts as a soft lubricating material and prevents the bonding between the layers. In order to evaluate the bond strength, the peeling test is used after cold roll bonding of Al strips with and without the addition of particles under different conditions. Results show that the bond strength increases with increasing the reduction in thickness, decreasing Gr content and performing the post-rolling annealing. During the multiple annealing and roll bonding process, the tensile strength increases with the cost of a small decrease in elongation. A relatively uniform distribution of particles is achieved at the last stages of the process. The Al/SiC-Gr hybrid composite exhibits an improved wear resistance compared with the monolithic Al and Al/SiC composite produced under the same conditions. The conclusion is drawn that a good combination of wear and mechanical properties can be achieved in the hybrid composite that has less amount of Gr.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Development of Technology for Detachment of Calandria Tube Rolled Joint of Pressurised Heavy Water Reactors

Coolant channel assembly of PHWRs consisting mainly of pressure tube and calandria tube undergoes sag due to irradiation enhanced creep during its life time. Typical service life of the pressure tube is limited to about 15 full power years due to such ageing related degradation. On account of the degradation the pressure tube needs replacement more than twice during the licensed period of reactor operation. As the sag in the calandria tube is also excessive, it has to be replaced to facilitate installation of new and straight pressure tube during retubing and to avoid interference of sagged calandria tube with horizontal reactivity devices. The calandria tube and the tube sheet are joined by sandwich type rolled joints. For detaching the joint an improved technique has been developed that helps to detach the joint without affecting the groove geometry and integrity of the tube sheet. The system works on the principle of fast thermal cycle of heating and cooling of the insert and calandria tube in the rolled joint region while applying axial load to the calandria tube. Though rolled joint detachment by induction heating technique has been in use in CANDU reactors for removal of pressure tubes and calandria tubes, the present design incorporates a liquid nitrogen for faster cooling and simultaneous application of load with a gripping module for detachment and removal of calandria tube and the insert from the tube sheet of end shield in shorter time. This paper describes the methodology of rolled joint detachment, challenges involved in the design, features of the detachment system, findings of experimental trials and observations.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2023

Operator inference with roll outs for learning reduced models from scarce and low-quality data

Data-driven modeling has become a key building block in computational science and engineering. However, data that are available in science and engineering are typically scarce, often polluted with noise and affected by measurement errors and other perturbations, which makes learning the dynamics of systems challenging. Here, in this work, we propose to combine data-driven modeling via operator inference with the dynamic training via roll outs of neural ordinary differential equations. Operator inference with roll outs inherits interpretability, scalability, and structure preservation of traditional operator inference while leveraging the dynamic training via roll outs over multiple time steps to increase stability and robustness for learning from low-quality and noisy data. Numerical experiments with data describing shallow water waves and surface quasi-geostrophic dynamics demonstrate that operator inference with roll outs provides predictive models from training trajectories even if data are sampled sparsely in time and polluted with noise of up to 10%.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2018

Texture simulation of a severely cold rolled low carbon steel using polycrystal modeling

Characteristic textures of cold-rolled low carbon steel consist of the RD//$\langle$110$\rangle$ fiber (α fiber) and ND//$\langle$111$\rangle$ fiber (γ fiber). Although the development of the γ fiber has been successfully modeled by the relaxed constraints polycrystal plasticity model, modeling of the α fiber has been less successful. Here, we investigate mechanisms underlying the development of a strong α fiber in a low carbon steel during cold rolling to large thickness reductions of 90%, 98%, and 99.8%. We compare the deformation textures measured using X-ray and electron backscatter diffraction methods with those simulated using polycrystal models, employing one of four homogenization schemes: the Taylor model, Secant model, Tangent model and an intermediate stiffness model between the Secant and Tangent models. The measured textures consist of an extremely strong α fiber and unusually weak γ fiber. The calculated textures achieve the best agreement with the measured ones when (1) the intermediate stiffness model is used to account for grain shape effects, (2) the flow rule exponent (n) is chosen to allow for multiple slip in grains, (3) latent hardening effects are suppressed, (4) $\langle$111$\rangle$ slip on {110}, {112} and {123} planes is made available for deformation, and (5) the grains shape is permitted to evolve individually. Taken together, these aspects represent indirectly the effects of cross slip on slip activity, suggesting that the strong α fiber in severely cold rolled steel results from cross slip. Although the cross slip is a well accepted mechanism in b.c.c. crystals, its connection to α fiber dominance in texture development during severe rolling deformation has not been established before.

36 MATERIALS SCIENCE↗