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At least 289 records · Page 16

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DOE OSTI2022

Mechanical behavior of bimetallic stainless steel and gray cast iron repairs via directed energy deposition additive manufacturing

The utility of gray cast iron in engine components remains tied to the mechanical performance and cost. Repair and remanufacturing of castings offer economical and sustainable benefits; however, high thermal input from traditional fusion-based welding is unable to restore the original mechanical quality owing to brittle microstructures and porosity formed in situ. Directed energy deposition (DED) is an additive manufacturing method that has received considerable interest for repairs owing to the highly controllable nature of the process. Despite this, few works have connected the effect of DED parameters on actual interfacial strength. Consequently, distinct DED parameter combinations were identified to maximize the strength and fatigue life of the repaired cast iron. Further, high speed melt pool imaging and residual stress measurements are provided to aid in the understanding of the metallurgical quality and strength seen in these structures. In general, higher scanning speeds and lower thermal gradients promoted comparable tensile strength to that of the original gray cast iron. The results presented here provide a foundation to tune in the DED process to generate the required mechanical quality as a starting point for future process advancements.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Designing Recyclable Biomass-Based Polyesters (Final Technical Report)

This project successfully demonstrated the production of sustainable polyesters from biomass-derived monomers, offering properties on par with or superior to fossil-based plastics such as LLDPE and PBAT. Using renewable chemical platforms like furfural and HMF, we synthesized over eight novel monomers and nearly 100 aliphatic-aromatic polyesters. Among these, PPeAT and PDDF emerged as highly promising candidates for flexible packaging applications, exhibiting excellent mechanical performance, tunable thermal properties, and enhanced barrier characteristics. Key advances included the development of ring-opening polymerization strategies using cyclic monomer intermediates to produce high molecular weight materials with excellent control. The resulting polymers achieved biobased content of at least 44 wt.%. We also implemented chemical recycling via catalytic methanolysis, recovering over 90% of monomers from PPeAT at semi-pilot scale. This supports a circular economy approach by enabling material reuse without performance loss. Techno-economic and life cycle assessments confirmed that these polyesters can reduce greenhouse gas emissions by up to 50% compared to petroleum-derived alternatives. Favorable mechanical properties may further reduce material demand, and cost competitiveness was demonstrated under specific market conditions. Feedstock cost and environmental footprint were identified as primary levers for future optimization. In summary, the project met or closely approached all technical targets, including biodegradability, strength, and processing compatibility. While minor issues such as color and melting point variation remain, the results strongly support continued development and scale-up of these sustainable materials.

09 BIOMASS FUELS↗

NASA NTRS1984

Nondestructive evaluation of composite materials - A design philosophy

Efficient and reliable structural design utilizing fiber reinforced composite materials may only be accomplished if the materials used may be nondestructively evaluated. There are two major reasons for this requirement: (1) composite materials are formed at the time the structure is fabricated and (2) at practical strain levels damage, changes in the condition of the material, that influence the structure's mechanical performance is present. The fundamental basis of such a nondestructive evaluation capability is presented. A discussion of means of assessing nondestructively the material condition as well as a damage mechanics theory that interprets the material condition in terms of its influence on the mechanical response, stiffness, strength and life is provided.

Duke, J. C., Jr.↗

NASA NTRS1989

Optomechanical design of the grating laser beam combiner (GLBC) laser diode header

A laser diode header has been fabricated for a grating laser beam combiner (GLBC). The laser diode header provides the thermal control, the drive electronics, and the optical system necessary for proper operation of the beam combiner. The diode header is required to provide diffraction limited optical performance while providing correction for worst case defocus aberration, 0.6 mrad excess divergence, and worst case decenter aberration, 1.0 mrad pointing error. The design of the header considered the mechanical design and the optical design together resulting in a small, self-contained header with 0.7 mrad range for focus correction and +/- 2.5 mrad of beam steering. The complete diode header is currently undergoing optical and mechanical performance testing.

Rall, Jonathan A. R.↗

DOE OSTI2026

A LASER POWDER BED FUSION ADDITIVE MANUFACTURING CHARACTERIZATION APPROACH AND DATASET HIGHLIGHTING IMPLICATIONS FOR CROSS-PLATFORM PERFORMANCE CONSISTENCY

Additive Manufacturing (AM) has remained a rapidly growing technology over the past decade, which affords many benefits. However, there is one main hinderance to widespread adoption: Products produced on one Laser Powder Bed Fusion (LPBF) AM system can vary in mechanical performance from those produced on another system. This is due to the fact that while LPBF AM system is producing a product’s shape, it is also producing the product’s material. Due to the complex and dynamic nature of LPBF, items fabricated on one system can be different in terms of dimensions, microstructure and quality compared to items fabricated on a different make or model system. This lack of cross-platform performance consistency makes widespread adoption challenging. This work was created to help understand the variation between different Laser Powder Bed Fusion (LPBF) Additive Manufacturing (AM) systems across different manufacturers, models, and users, and to provide insight into how to ensure product consistency regardless of system selection.

36 MATERIALS SCIENCE↗

NASA NTRS1995

Effects of low earth orbit on the optical performance of multi-layer enhanced high reflectance mirrors

Two mirror designs developed for space applications were flown along with a standard mid-infrared design on the leading and trailing edges of the Long Duration Exposure Facility (LDEF). Preliminary observations of induced changes in optical performance of ZnS-coated mirrors and impact-related microstructural and microchemical effects are described in the proceedings of the First LDEF Post-Retrieval Symposium. In this paper, effects of the induced environment and meteoroid/debris impacts on mirror performance are described in more detail. Also, an analysis of reflectance spectra using the results of Auger and secondary ion mass spectroscopy (SIMS) profiling measurements are used to identify an optical-degradation mechanism for the ZnS-coated mirrors. Structural damage associated with a high-velocity impact on a (Si/Al2O3)-coated mirror was imaged optically and with scanning electron and atomic force microscopy (SEM and AFM). Scanning Auger and SIMS analysis provided chemical mapping of selected impact sites. The impact data suggest design and fabrication modifications for obtaining improved mechanical performance using a design variation identified in preflight laboratory simulations. Auger surface profile and SIMS imaging data verified the conclusion that secondary impacts are the source of contamination associated with the dendrites grown on the leading-edge ZnS-coated test samples. It was also found that dendrites can be grown in the laboratory by irradiating contaminated sites on a trailing-edge ZnS-coated sample with a rastered electron beam. These results suggest a mechanism for dendrite growth.

Donovan, Terence↗

DOE OSTI2023

Creep-Resistant Ferritic-Martensitic Steels for Power Plant Applications

Creep-resistant ferritic-martensitic steels are essential materials used in power plants for electricity generation. The efficiency and emissions of the plant are closely related to the operating temperature. Materials used in the hottest sections are one of the main limiting factor for plant operation at 650 °C. This review describes the recent development of creep-resistant ferritic-martensitic steels from a large dataset of in-house research. The findings are tied to available literature for discussion. A first steel, CPJ-7, was developed with an operating temperature approaching 650 °C, and a refined design, JMP, showed the potential to operate at 650 °C. Approximately fifty different ingots, each weighing ~ 7 kg, were vacuum induction melted and processed. Overall, wrought and cast versions of CPJ-7 present superior creep properties when compared to wrought and cast versions of COST alloys for steam turbine and P91/92 for boiler applications. The prolonged creep life was attributed to slowing down the process of the destabilization of the MX and M 23 C 6 precipitates at 650 °C. The cast version of CPJ-7 also revealed superior mechanical performance, above commercially available cast 9% Cr martensitic steel or derivatives. Following the work on CPJ-7, the JMP steels were designed with higher Co for increased solid solution strengthening, Si for oxidation resistance and increased W for matrix strength and stability. The JMP steels showed increases in creep life compared to CPJ-7 between 118 and 150% at 650 °C for testing at various stresses between 138 and 207 MPa. On a Larson–Miller plot, the performance of the JMP steels surpasses that of state-of-the-art MARBN steel. The influence of various elements within the composition of the alloys on the microstructure and mechanical properties is discussed. This review presents approximately 420,000 h of in-house creep testing, the equivalent of almost 50 years of cumulative creep tests.

36 MATERIALS SCIENCE↗

NASA NTRS1972

Study of low-cost fabrication of ablative heat shields

The major objectives were accomplished in three tasks: (1) modification of the ablative material composition for ease of fabrication as well as thermal and mechanical performance; (2) scaled-up, simplified, manufacturing techniques which resulted in cost reductions; and (3) the identification of a significant design problem caused by the differential pressure buildup imposed on mechanically attached ablative heat shield panels during launch.

Norwood, L. B.↗

NASA NTRS1986

Large space reflector technology on the Space Station

This paper discusses the role of the Space Station in the evolutionary development of large space reflector technology and the accommodation of mission systems which will apply large space reflectors during the late 1990s and the early part of the next century. Reflectors which range from 10 to 100 meters in size and which span the electromagnetic spectrum for applications that include earth communications, earth observations, astrophysics and solar physics, and deep space communications are discussed. The role of the Space Station in large space reflector technology development and system performance demonstration is found to be critical; that role involves the accommodation of a wide variety of technology demonstrations and operational activities on the Station, including reflector deployment and/or assembly, mechanical performance verification and configuration refinement, systematic diagnostics of reflector surfaces, structural dynamics and controls research, overall system performance characterization and modification (including both radio frequency field pattern measurements and required end-to-end system demonstrations), and reflector-to-spacecraft integration and staging. A unique facility for Space Station-based, large space reflector research and development is proposed. A preliminary concept for such a Space Station-based Large Space Reflector Facility (LSRF) is described.

Mankins, J. C.↗

DOE OSTI2025

Toolpath Optimization of Polymer Composite Additive Manufacturing AM Printed Mold to Improve Performance for Compression Molding Applications

This study explores the optimization of toolpaths for short fiber polymer composite additive manufacturing (AM) printed molds in compression molding applications, an emerging trend driven by advancements in 3D printing technology. AM printed molds offer reduced tooling costs and greater design flexibility, particularly for prototyping and low-volume production. The proposed optimization approach evaluates mold performance using two key metrics: deformation and shape accuracy. Multiple toolpaths are generated, and finite element (FE) simulations capture fiber orientation and material properties, which are then integrated into a mechanical performance model. Shape accuracy is assessed by comparing the deformed mold shape with the original using surface normals as a descriptor. The analysis identifies the toolpath that delivers the best overall performance, establishing it as the most suitable option for achieving optimal mold characteristics in compression molding applications.

Limaye, Madhura [ORNL]↗

DOE OSTI2025

Mineralized sclerites in the gorgonian coral Leptogorgia chilensis as a natural jamming system

The soft corals (Cnidaria, Octocorallia), a diverse group of colonial marine invertebrates, can reversibly tune their body stiffness in response to external stimuli. This capability is attributed to their dynamic skeletal systems, which consist of thousands of mineralized skeletal elements, called sclerites, embedded within a gel-like matrix that swells/deswells and unjams/jams the sclerites, thus modulating skeletal stiffness. While sclerite morphology is widely used for species identification, its role in the mechanical performance of a soft coral’s skeletal system is largely unknown. Here, we investigated structure-jamming relationships in sclerite-based skeletal architectures using the red gorgonian octocoral Leptogorgia chilensis as a model system. The sclerites of L. chilensis exhibit a shaft-like geometry with two axial branches and two sets of triradiate side branches, which are aligned with the crystallographic symmetry of the constituent magnesium-containing calcite. By combining multiscale three-dimensional (3D) structural characterization, parametric geometrical modeling, 3D printing, mechanical testing, and discrete element simulations, we demonstrate how sclerite geometry achieves a balanced jamming performance in terms of stiffness, weight, strength, and fracture resistance in comparison to alternative geometries parametrically modified from the native sclerites (e.g., changes in the length and number of side branches). Here, we also found that these performance metrics are achieved through the effective interlocking among side and axial branches, which is further enhanced by the fractal-like microscopic spikes on the branch tips. The findings in this natural jamming system offer insights for designing synthetic mechanotunable material architectures for a wide range of applications, from soft robotics to mechanical dampeners.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Fiber orientation effects on ultra-high performance concrete formed by 3D printing

Despite the growing interest in 3D concrete printing, its current progress is limited by reinforcing methods. Inclusion of steel fibers is a potential reinforcing solution; however, the effect of printing process on orientation of the fibers is still unknown. This study aims to quantitatively investigate the orientation distribution of steel fibers in 3D printed ultra-high performance concrete. The effects of extrusion nozzle size, Cartesian print speed, and fiber volume fraction on the orientation of fibers were evaluated using digital image analysis. The consequent effects of the fiber orientation on the mechanical properties of the 3D-printed specimens were also determined. The results were compared with those of the conventionally mold-cast specimens. The results revealed that the smaller nozzle size and higher fiber volume fraction significantly enhanced the fiber alignment parallel to the printing direction. This preferential fiber alignment led to superior mechanical performance of the printed specimens to the mold-cast specimens.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Data-Driven Surrogate Modeling with Microstructure-Sensitivity of Viscoplastic Creep in Grade 91 Steel

Abstract To support the development of advanced steel alloys tailored to withstand extreme conditions, it is imperative to account for the mechanical performance of components, while considering the influence of local microstructure on the macroscopic response. To this end, this study focuses on the development of microstructure-sensitive constitutive models for the mechanical response of Grade 91 steel exposed to extreme thermo-mechanical environments. Polynomial chaos expansion (PCE) surrogates are used to emulate high-fidelity polycrystal simulations of the viscoplastic response of Grade 91 steel as a function of the microstructure fingerprint (e.g., dislocations and precipitates). To cover a wide temperature–stress domain, two separate PCE surrogates—one that captures softening and the other that captures hardening behavior—are combined using another (sparse) Gaussian process regression model. The resulting constitutive creep surrogate model is integrated within the MOOSE finite element framework to simulate the intricate effects of microstructure, in particular MX-phase precipitates, on a component with a graded microstructure. Surrogate sensitivity analysis is applied to quantify the relevant impact of spatially varying microstructure on the creep response in a test-case involving a Grade 91 alloy with a prototypical weld.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Report on the FY20 Characterization of Age Hardened Alloy 709 Materials

This report provides the results on microstructural characterization of the first commercial heat of Alloy 709 plate material undergone additional age hardening treatment. In FY19, through thermodynamic-kinetic modeling and microstructural characterization, it is determined that the 775°C/10 h age-hardening treatment can promote desired precipitation on dislocations and has the potential to further improve the mechanical performance of the material. In FY20, the treatment protocol was applied to the ESR-1150°C condition, and the microstructure was then compared with the ESR-1100°C condition. It was found that the 1150°C solution annealing (SA) dramatically reduced the dislocation density compared to the 1100°C SA, resulting a smaller number density of Nb-rich fine precipitates which grow on dislocations during the age hardening treatment. Other features are very similar between the two. The effect of age hardening on creep performance is discussed. In addition, TEM characterization of a creep-ruptured sample (600°C/330 MPa) was performed. Specimens from the grip region and the gauge region was studied. The grip region specimen was effectively aged at 600°C for extended period, while the gauge region specimen was mechanically deformed at 600°C. The microstructures are very different, implying the importance of a dynamical effect on precipitation.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

NASA NTRS1976

Space shuttle L-tube radiator testing

A series of tests were conducted to support the development of the Orbiter Heat Rejection System. The details of the baseline radiator were defined by designing, fabricating, and testing representative hardware. The tests were performed in the Space Environmental Simulation Laboratory Chamber A. An IR source was used to simulate total solar and infrared environmental loads on the flowing shuttle radiators panel. The thermal and mechanical performance of L tube space radiators and their thermal coating were established.

Phillips, M. A.↗

NASA NTRS1992

SOHO MAMA openable cover/vacuum seal mechanism

The requirements, design, and test results of an openable cover mechanism with a high-vacuum seal developed for the Multi-Anode Microchannel Array (MAMA) Detectors, aboard the Solar and Heliospheric Observatory (SOHO) spacecraft. The mechanism, tested in summer/fall of 1991, has completed 1000 test cycles in an inert atmosphere at room temperature and pressure. Measured mechanism performance included: vacuum seal less than 5 x 10 exp -10 torr-liter/second, 103 degree angular range of travel, 20-minute cycle time, and successful latching functions. An openable cover mechanism that provides a clean, high-vacuum seal is vital to the success of a MAMA Detector operating over a full wavelength coverage from 500 to 1600 A.

Wiens, Mitchell T.↗

DOE OSTI2021

Impact of Coating Defects on Performance of Coated Zirconium Cladding

Research on accident tolerant fuels (ATF) has started after the Fukushima accident [1–3]. While efforts have been expended on both fuel and cladding ATF concepts, the bulk of work has been devoted to improved cladding. The overarching goal of these approaches is to extend the coping time available during a severe accident before any event would result in release of radioactivity to the public. The most basic ATF cladding concept is obtained by applying a thin coating of highly corrosion-resistant material on the surface of a licensed zirconium cladding alloy. This thin coating is intended to not interfere with the neutronic or mechanical performance of the base cladding under normal operating conditions. Different coating materials, thicknesses, coating processes, process parameters, and testing methods have an impact on the microstructure and mechanical properties and therefore on the results of the applied investigation methods. These challenges have motivated an initial focus on demonstrating that the presence of coatings do not perturb the critical performance benchmarks of uncoated material. Ongoing lead test assembly irradiations of coated zirconium concepts in commercial reactions is intended to establish baseline performance in this regard in the coming years.

36 MATERIALS SCIENCE↗

DOE OSTI2023

LANL end of the year report (2023)

This report summarizes the advances made by LANL in the XMAT-H2 program over FY23. In summary LANL was tasked with leading efforts related to (1) the development of models predicting hydrogen (H) redistribution within polycrystals (H redistribution model), (2) the development of models for the mechanical performance of metals/steels under H environments (Model for H effects on plasticity), The development of a framework to quantify the uncertainty in model parameters (Uncertainty in model parameters), (3) small scale characterization of the mechanical response of 347H (Microstructure characterization).

08 HYDROGEN↗