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At least 307 records · Page 17

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DOE OSTI2026

Evaluating transient fission gas release in high burnup light water reactor fuel during loss of coolant accident conditions via new capabilities

In this work, the role of transient fission gas release (tFGR) in the cladding burst behavior of high burnup fuel during a loss-of-coolant accident (LOCA) in commercial light water reactors was further investigated via the use of a new apparatus. During the LOCA-related temperature ramps of high burnup fuel, the release of fission gases exceeds the steady-state release observed under normal operating conditions. An enhancement was made to the Oak Ridge National Laboratory Severe Accident Test Station (SATS) to probe the various factors influencing tFGR. Experiments were performed on commercially irradiated, zirconium-clad uranium dioxide fuel, and this paper details the design of the experimental setup, the initial test results, and the subsequent post-test analyses. Notably, the first test on high burnup fuel demonstrated a LOCA-relevant tFGR of 5.3% from an unpressurized fuel segment. The ultimate tFGR was 10.7% for beyond LOCA conditions. A follow-up test on similar fuel revealed a tFGR of 12.6% under comparable conditions. Microstructural analysis and an analysis of the released gas provide some insight regarding the source of tFGR in the fuel. Finally, a grain boundary bubble model may aid in the interpretation of the results and offer a guide for future work.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Mechanistic Insights Into Fatigue Life Enhancement of High‐Strength Steel via Ultrasonic Impact Treatment

In this work we explore the impact of Ultrasonic Impact Treatment (UIT) on the fatigue performance of high‐strength microalloyed steel commonly used in crankshaft applications. Building on prior observations of fatigue life improvement with UIT, this work focuses on unraveling the process–structure–performance relationships underpinning these enhancements. Microstructural analysis revealed significant grain refinement in the near‐surface layers, with deformation depth increasing at higher impact energies. This led to increased surface hardness and the development of deeper compressive residual stresses, particularly in samples treated with higher impact energy. Rotating bending fatigue testing showed a substantial improvement in fatigue life for UIT‐treated samples, with the endurance limit nearly doubling compared with untreated specimens. Fractographic analysis revealed a transition in crack initiation from surface defects in untreated samples to interior regions in UIT‐treated samples, characterized by the formation of noninclusion‐induced granular bright facets (GBFs). The observed fatigue enhancement is attributed to the synergistic effects of strain hardening and compressive residual stresses, which increase the surface crack threshold and promote interior crack initiation. This study provides new mechanistic insight into UIT‐induced fatigue resistance and interior failure behavior in high‐strength steels.

36 MATERIALS SCIENCE↗

NASA NTRSDate not supplied

Computational Investigation of Oxidative Etch Pitting in FiberForm and Its Impact on Material Properties

Oxidation-driven carbon erosion does not occur uniformly but rather through the development of localized etch pits at active surface sites. These active sites form due to atomic defects on the carbon surface, making them significantly more reactive than the surrounding, non-defective areas. As a result, these sites are the first to react during ablation, leading to their removal. This process creates new defects in neighboring atoms, increasing their reactivity and causing localized carbon removal around these active sites. In this way, the highly reactive defective areas serve as nucleation points for the formation and growth of etch pits, which can have adverse effects on structural integrity of FiberForm. To better understand how these etch pits impact the material properties of carbon fiber microstructures, we have developed a new capability within the direct simulation Monte Carlo (DSMC) framework to capture the etch pit formation process. This capability, integrated into the DSMC code SPARTA (Stochastic Parallel Rarefied-gas Time-accurate Analyzer), models material removal in the presence of active sites, leading to the formation of etch pits. The current work focuses on studying the effects of these etch pits on the material properties of FiberForm, a widely used base material in thermal protection systems (TPS). The microstructure of virgin FiberForm, obtained via X-ray microtomography, is imported into SPARTA to generate the ablated geometries with etch pits. These modified microstructures are then analyzed using the Porous Microstructure Analysis (PuMA) software to compute various material properties, including elasticity, thermal conductivity, and permeability. We investigate the variation of these properties due to the complex surface topology changes caused by etch pit formation. Additionally, we compare the effects of pitting with the conventional model of shrinking fibers, traditionally used to simulate the ablation of carbon structures. Significant differences emerge between the two approaches. Consequently, this physically realistic model of material removal through etch pit formation offers improved accuracy in predicting the degradation of carbon-based TPS during oxidation. It also provides insights into other mechanisms, such as spallation, where chunks of material are removed into the flow due to etch pit growth. Ultimately, this model enhances our understanding of failure modes in these materials during ablation.

PuMA↗

DOE OSTI2018

Changes in the microstructure and mechanical properties of additively manufactured AlSi10Mg alloy after exposure to elevated temperatures

Highlights: • Elevated temperatures above 120 °C brought changes to the AM AlSi10Mg alloy. • A maximum hardness state obtained at 160 °C/5 h was thoroughly tested. • Hardness increased by 15% and TYS by 5%, but elongation dropped by 60%. • Pure Si precipitates were responsible for the observed changes. - Abstract: The additive manufacture (AM) of the AlSi10Mg alloy has become the subject of considerable attention, especially for production of complex parts in engines. Because such parts can be exposed to elevated temperatures during operation, material stability is very important, but as yet little is known about it in relation to AM. Here, we studied changes of the AlSi10Mg alloy produced by selective laser melting (SLM) after its exposure to temperatures between 120 and 180 °C. At each temperature, hardness evolution was measured, with hardness increasing over time. The maximum hardness state obtained at 160 °C was selected for further studies comprising microstructural analysis by scanning and transmission electron microscopy, chemical composition analysis and mechanical properties assessment. Transmission microscopy revealed nano-scale acicular precipitates that caused a slight increase in the yield strength of the alloy together with a significant drop in elongation. Electron energy loss spectroscopy (EELS) and energy dispersive spectroscopy (EDS) showed that the precipitates surprisingly consisted of pure Si. To provide a comparison, conventional regimes of heat treatment (stress-relief and T6) were applied. Despite a considerable loss in mechanical performance, thermal instability was no longer observed. Overall, our results indicate that operating temperatures are a key factor in ensuring the smooth operation of AM parts of the AlSi10Mg alloy. In respect to that, we offer recommendations for their industrial use.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Effects of Nb on the Microstructure and Properties of Ti-Added Hypereutectic High-Cr Cast Iron

Effects of Nb on the microstructure and properties of Ti-added hypereutectic high-Cr cast iron were studied. With the addition of Nb, a new phase (Nb,Ti)C was formed. The microstructure analysis revealed that the amount of primary carbides was decreased from 18.6 to 8.8% and the primary and eutectic carbides were greatly refined. The decrease in the amount of primary carbides was attributed with the shrinking of primary M{sub 7}C{sub 3} phase zone in the phase diagram, while the refinement of primary carbides was attributed to the heterogeneous nucleus of (Nb,Ti)C phase for the primary M{sub 7}C{sub 3} carbides. The macrohardness of the alloy increased from 60.8 to 63.5HRC, and the impact toughness increased from 3.8 to 5.2 J cm{sup −2}. Furthermore, the wear resistance was enhanced with the addition of Nb due to the formation of hard (Nb,Ti)C carbides.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Effect of Solution Treatment on the Microstructure, Micromechanical Properties, and Kinetic Parameters of the β → α Phase Transformation during Continuous Cooling of Ti-6Al-4V Titanium Alloy

The aim of this study is to examine the effect of solution treatment temperature (STT) on the microstructure, the micromechanical properties, and the kinetic parameters of the β → α phase transformation during continuous cooling of the dual phase titanium alloy Ti-6Al-4V. Increasing the STT from 1050 to 1200 °C delays the formation of the α phase during cooling and increases the value of its activation energy. The microstructural analysis reveals the emergence of α{sub W} platelets from protuberances on the α{sub GB}/α{sub W} interface. The investigation of the morphology of the α{sub W} platelets reveals the presence of ledges on their longest side showing a sharp extremity. The micromechanical properties determined by nanoindentation and microhardness tests are almost insensitive to the cooling rate but are strongly affected by the STT; the higher the STT, the lower the overall microhardness of the Ti-6Al-4V alloy. In addition, the STT affects the microhardness and the Young’s modulus of both α and β phases differently; when the STT increases, the microhardness and the Young’s modulus of the α phase decrease, whereas those of the β phase increases.

36 MATERIALS SCIENCE↗

DOE OSTI2016

Visible-active photocatalytic behaviors observed in nanostructured lead chalcogenides PbX (X = S, Se, Te)

Nanostructured lead chalcogenides (PbX, X = Te, Se, S) were prepared via a simple hydrothermal method. The powder samples were characterized by XRD, SEM, SAED and DRS. Phase composition and microstructure analysis indicate that these samples are pure lead chalcogenides phases and have similar morphologies. These lead chalcogenides display efficient absorption in the UV-visible light range. The photocatalytic properties of lead chalcogenides nanoparticles were evaluated by the photodegradation of Congo red under UV-visible light irradiation in air atmosphere. The Congo red solution can be efficiently degraded under visible light in the presence of lead chalcogenides nanoparticles. The photocatalytic activities of lead chalcogenides generally increase with increasing their band gaps and shows no appreciable loss after repeated cycles. Our results may be useful for developing new photocatalyst systems responsive to visible light among narrow band gap semiconductors.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Hybrid fiber metal composite laminate interlaminar reinforcement through metal interlocks

Aircraft and automobile industries are continually seeking high-performance and lightweight solutions. Fiber-reinforced composites in conjunction with metals are being considered in the form of hybrid materials. There is a continuous need for improvement of interfacial bonding between composite layers and metal constituents. In this study, an innovative hybrid fiber interlocking metal hooks laminate (FIMHL) system was developed in which fiber-reinforced thermoset composite, and metal sheets are mechanically bonded together using out of plane hooks stamped in the metal. Process optimization was performed to gain the full benefit of the through-thickness reinforcement. Microstructural analysis showed improved interaction between the metal hooks and the fiber layers which reduced porosity and resin richness. This was reflected in mechanical properties, as tensile and flexural strength of FIMHL was enhanced by 38.5 and 18.8%, respectively, after process optimization. Furthermore, normalized weight fraction (76.4%) properties of FIMHL also confirmed that the increase in mechanical properties of optimized panel were not only due to increased reinforcement (glass fiber + aluminum) volume fraction but also because of improved metal hooks and fibers interaction. There was no significant effect on lap shear and fracture toughness, as they depend on bend back behavior of the hooks. A bilinear traction-separation model was used to characterize mode-I interlaminar fracture toughness properties, and 4.5% variation was recorded when modeling and experimental values were compared.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Improvement of circumferential ductility by reducing discontinuities in a high-Mn TWIP steel weldment

Highlights: • This study focused on two key ways to improve expandability of TWIP steel pipe. • The amount of penetrator is remarkably reduced at low PO{sub 2} welding atmosphere. • The effect of PWHT on the morphological change in the bond line was characterized. - Abstract: Recently, high-frequency electrical resistance welded (HF-ERW) pipes have been introduced as an application of high-Mn twinning induced plasticity (TWIP) steels. However, the excellent ductility of the TWIP steels has been underutilized in expandable pipe applications due to discontinuities in the weldment. This work presents two key ways to improve the pipe expandability or circumferential ductility. In-depth microstructural analysis and flaring tests were conducted to identify bond line discontinuities and to evaluate the circumferential ductility. These results indicate that ductility formed to be strongly related to the welding atmosphere and post-weld heat treatment (PWHT) conditions. The welding atmosphere was related to oxide defects, while the PWHT conditions were related to intrinsic discontinuities. The distribution and amount of penetrator defects along the bond line are the main factors related to the deterioration of the circumferential ductility, which is affected by the sheet metal compositions and decreased remarkably at low PO{sub 2} content. We also suggest that PWHT is necessary for improving the ductility by inducing changes in the bond line texture and hardness distribution. The results were verified based on changes in the crack path propagation.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Development of Stretch Flangeable Grade Steels by Inclusion Engineering Approach

The demand for good stretch flangeability in high-strength automotive steels has necessitated due attention on steel cleanliness and processes. The presence of elongated MnS stringers and centerline segregation of nonmetallic inclusions adversely affects the transverse mechanical property. In the present investigation, stretch flangeability of industrially produced steel, with and without Ca treatment, has been compared with Ti-added steel, produced at 40 kg scale without Ca treatment. The study brings out the influence of centerline segregation and modification of nonmetallic inclusions on HER performance. The microstructural analysis of industrial steel revealed that the method of hole formation (punching/drilling) determines crack initiation mechanism. The inclusions, along with the second phase present in the centerline, drive the crack propagation. An addition of Ti in liquid steel promotes formation of Al-Ti-O-based oxide, prior to MnS precipitation, during solidification and acts as nucleation site for MnS inclusion. This obviates the elongated stringer-type MnS inclusions. The centerline segregation-free Ti-modified steel, prepared at the laboratory scale, showed consistent HER property compared with industrial steel. It is also concluded that calcium treatment can be circumvented by modifying the sulfide stringer with the addition of Ti in the steel for further improvement in HER property.

36 MATERIALS SCIENCE↗

DOE OSTI2013

Characterization of 430L porous supports obtained by powder extrusion moulding for their application in solid oxide fuel cells

The characterization of 430L stainless steel planar porous supports obtained by powder extrusion moulding was performed in this work. A thermoplastic multicomponent binder based on high density polyethylene and paraffin wax was selected for the process. Green supports were shaped by extrusion moulding, and subsequently the binder was removed by a thermal cycle previously optimized. Sintering was carried out at different temperatures in low vacuum. Density of sintered parts was measured by Archimedes' method and porosity was also evaluated through a microstructural analysis by optical microscopy. The porosity degree of samples sintered at low temperature was close to 35% which is a very suitable value for their application in SOFCs. Tensile tests were carried out in order to determine mechanical strength as a function of porosity degree. Based on these results, the best feedstock composition and processing parameters were selected. The oxidation behaviour in static air at high temperature was studied, and formed oxides were characterized in a scanning electron microscope equipped with energy dispersive analysis of X-rays. X-ray diffraction experiments were performed in order to identify the formed oxides based on formula Fe{sub 2−x}Cr{sub x}O{sub 3}. The results of these studies showed that this kind of ferritic stainless steel would be more suitable to be used as anodic supports where a rich hydrogen atmosphere is employed. Preliminary deposition tests allowed obtaining a homogeneous Ni–YSZ anode layer with a thickness of 10 μm on the porous metallic substrates. - Highlights: • 430L stainless steel porous supports were obtained by powder extrusion moulding. • Porosity degree was controlled sintering at different temperatures in low vacuum. • Tensile tests allowed determining mechanical strength of porous supports. • A study about its oxidation behaviour in static air at high temperature was realized. • After oxidation, formed oxides were characterized by EDS–SEM and XRD.

36 MATERIALS SCIENCE↗

NASA NTRSDate not supplied

Computational Study of Oxidative Etch Pitting in FiberForm and the Effect on Its Material Properties

Erosion of carbon due to oxidation does not occur uniformly but through the formation of localized etch pits because of active surface sites. These active sites are formed due to the presence of atomic defects on the carbon surface, and have much higher reactivity compared to average non-defective sites. Thus, these active sites are first to react during ablation, resulting in their removal. This causes all the neighboring atoms to be defective and increase their reactivity, thus leading to the localized carbon removal around these “active” sites. In this manner, these highly reactive defective sites serve as nucleation sites for the formation and growth of etch pits with potentially detrimental effects on the structural integrity. In order to understand the influence of these etch pits on the material properties of carbon fiber microstructures, we have developed a new capability within direct simulation Monte Carlo (DSMC) to capture the etch pit formation process. This capability is developed within the DSMC code SPARTA (Stochastic PArallel Rarefied-gas Time-accurate Analyzer) and can model the material removal in presence of active sites leading to the formation of etch pits. The focus of the current work will be to study the effect of etch pits on the material properties of FiberForm, a commonly used base material within many thermal protection system materials (TPS). The microstructure of virgin FiberForm obtained directly from X-ray microtomography experiments is used within SPARTA to obtain the ablated geometries with etch pits. These pitted microstructures are then imported within the Porous Microstructure Analysis (PuMA) software and various material properties such as elasticity, thermal conductivity, and permeability are computed. The variation of these properties as a result of the complex evolution of the surface topology due to etch pit formation is studied and analyzed. Furthermore, the effect of pitting is compared to the case of shrinking fibers, which has been the standard for modelling ablation of carbon structures; and significant differences are observed. Thus, such a physically realistic modeling of material removal through the formation of etch pits will be helpful in predicting the degradation of carbon-based TPS more accurately during oxidation; as well as other mechanisms such as spallation, which involves the removal of chunks of material into the flow due to etch pit growth. This will ultimately improve our understanding of the failure modes in these materials due to ablation.

Carbon Ablators↗

NASA NTRSDate not supplied

Computational Study of Oxidative Etch Pitting in FiberForm and the Effect on Its Material Properties

Carbon Ablators↗

DOE OSTI2014

Impacts of crystal orientation of GaAs on the interfacial structures and electrical properties of Hf{sub 0.6}La{sub 0.4}O{sub x} films

One of the major challenges in realizing the GaAs channel in the metal oxide semiconductor field effect transistor is the degrading in electron transport properties at the interface between GaAs and the gate oxide. In this study, Hf{sub 0.6}La{sub 0.4}O{sub x} gate oxide films were deposited at a low temperature (200 °C) on GaAs(111)A and GaAs(100) substrates by plasma enhanced atomic layer deposition. Microstructure analysis indicates that residuals of gallium oxide, arsenic oxide, and As element remained at the interface of Hf{sub 0.6}La{sub 0.4}O{sub x}/GaAs(100). On contrast, a smoother interface is observed between Hf{sub 0.6}La{sub 0.4}O{sub x} thin film and GaAs(111)A substrate. Furthermore, a reduction of interfacial layer is observed in Hf{sub 0.6}La{sub 0.4}O{sub x}/GaAs(111)A. Electrical characterization of the metal-insulator-semiconductor Pt/Hf{sub 0.6}La{sub 0.4}O{sub x}/n-GaAs(111)A capacitor indicated a reduction of D{sub it} and leakage current compared with the capacitor fabricated on GaAs(100)

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2017

Heat-Treated TiO{sub 2} Plasma Spray Deposition for Bioactivity Improvement in Ti-6Al-4V Alloy

In the present study, titanium di-oxide (TiO{sub 2}) coating has been developed on Ti-6Al-4V substrate by plasma spray deposition. Followed by plasma spraying, heat treatment of the sprayed sample has been carried out by isothermally holding it at 823 K (550 °C) for 2 h. Microstructural analysis shows the presence of porosity and unmelted particles on the as-sprayed surface, the area fraction of which reduces after heat treatment. X-ray diffraction analysis shows the phase transformation from anatase (in precursor powder) to rutile (in as-sprayed coating and the same after heat treatment). There is an improvement in nano-hardness, “Young’s modulus” and wear resistance in plasma-sprayed TiO{sub 2} coating (as-sprayed as well as post-heat-treated condition) as compared to as-received Ti-6Al-4V, though post-heat treatment offers a superior hardness, “young’s modulus” and wear resistance as compared to as-sprayed coating. The corrosion behavior in “hank’s solution” shows decrease in corrosion resistance after plasma spraying and post-heat treatment as compared to as-received substrate. A significant decrease in contact angle and improvement in bioactivity (in terms of apatite deposition) were observed in TiO{sub 2}-coated surface as compared to as-received Ti-6Al-4V.

36 MATERIALS SCIENCE↗

DOE OSTI2018

The Effect of Boron and Zirconium on the Structure and Tensile Properties of the Cast Nickel-Based Superalloy ATI 718Plus

The effects of boron and zirconium on cast structure, hardness, and tensile properties of the nickel-based superalloy 718Plus were investigated. For this purpose, five alloys with different contents of boron and zirconium were cast via vacuum induction melting and then purified via vacuum arc remelting. Microstructural analysis by light-optical microscope and scanning electron microscope equipped with energy-dispersive x-ray spectroscopy and phase studies by x-ray diffraction analysis were performed. The results showed that boron and zirconium tend to significantly reduce dendritic arm spacing and increase the amount of Laves, Laves/gamma eutectic, and carbide phases. It was also found that boron led to the formation of B{sub 4}C and (Cr, Fe, Mo, Ni, Ti){sub 3}B{sub 2} phases and zirconium led to the formation of intermetallic phases and ZrC carbide. In the presence of boron and zirconium, the hardness and its difference between dendritic branches and inter-dendritic spaces increased by concentrating such phases as Laves in the inter-dendritic spaces. These elements had a negative effect on tensile properties of the alloy, including ductility and strength, mainly because of the increase in the Laves phase. It should be noted that the largest degradation of the tensile properties occurred in the alloys containing the maximum amount of zirconium.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Spatial and temporal characterization of municipal solid waste based on resource recovery pathways

This study presents a two-year, quarterly assessment of MSW across four source sectors (residential, schools, restaurants, and grocery stores) from sixteen sites across five U.S. states. MSW was manually sorted into 27 categories and aggregated into pathway fractions: high-moisture (HM) organics, low-moisture (LM) organics, recyclable (RC) materials, and residuals for disposal. Organics represented 89 % of the MSW stream. The largest fraction was HM organics consisting of food waste (31 %) and yard waste (3 %), with large coefficient of variations (CV), 79 and 278 %, respectively, reflecting high seasonal and site variability that varied significantly (p < 0.01) across sampling periods. The HM fraction showed properties favorable for anaerobic digestion, with moisture content ranging from 56 to 95 % and volatile solids ranges of 86-95 %. In contrast, the LM and RC fractions remained more stable (plastics CV = 41 %; paper CV = 53 %) with heating values up to 26.9 MJ/kg across sources, reflecting suitability for gasification. Microstructural analysis revealed less porosity in residential waste sampled at the landfill, which can influence preprocessing efficiency and microbial accessibility. Pathway informed allocations showed that 35 % of MSW is suitable for anaerobic digestion, 36 % for gasification, and 18 % for recycling, leaving 11 % requiring landfill disposal. These results provide quantitative evidence to determine feedstock allocation, waste-to-energy system design, and the development of data-driven sustainability and resource recovery strategies within a circular bioeconomy.

09 BIOMASS FUELS↗

DOE OSTI2018

Microstructure characterisation of un-melted particles in a plasma sprayed CoNiCrAlY coating

Highlights: • The microstructure of the CoNiCrAlY powder particles was studied. • The un-melted particles in the VPS CoNiCrAlY coating were investigated. • A semi-continuous β-phase layer was found around the un-melted particles. • Micro-cracks were formed along the un-melted particles under compression. - Abstract: Un-melted particles in thermally sprayed coatings are usually classified as impurity elements. Such impurities have a strong influence on the coating behaviour due to their different microstructural characteristics. In this work, the microstructural and mechanical characteristics of un-melted particles in a vacuum plasma sprayed CoNiCrAlY coating have been investigated. Microstructural analysis revealed the dendritic structure of the as-received powder and a spherical core inside the powder particle. The as-deposited coating comprised a dual phase structure of γ-Ni and β-NiAl, with coarse grains ranging 1–2 μm and fine grains ranging 500 nm or even less. Un-melted particles were found to exist in the coating after plasma spraying. The grain structure in the un-melted particles has not been fully developed, as characterised via electron backscattered diffraction (EBSD). It is shown that the spherical core in the initial powder was retained as un-melted particles due to insufficient melting during plasma spraying. In addition, a semi-continuous β-phase layer was found at the un-melted particle boundaries. Due to the inherently brittle nature of the β-phase layer and poor bonding at the particle boundaries, cracking along the un-melted particle boundaries occurred under compression.

36 MATERIALS SCIENCE↗