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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 307 records · Page 17
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Predicting Geometric Influences in Metal Additive Manufacturing

Metal additive manufacturing (AM) has evolved from scientific curiosity to a potential paradigm shift in materials manufacturing owing to its ability to control microstructure and fabricate complex geometries. However, geometry, often ignored as a variable, can have a significant impact on microstructure evolution, thereby indirectly limiting the design flexibility offered by AM. Currently, the process of retaining microstructure with changing geometry relies on trial and error-based processing followed by microstructural evaluation that places significant demands on time and costs associated with experimentation and characterization. We demonstrate herein that lightweight thermal models can be effectively used to predict microstructural changes with geometry. These models can in turn be used as precursors to developing geometry independent scan strategies and achieve microstructure control in various alloy systems. Even if the thermal signatures predicted by the model are not accurate, scan strategies can be developed to mimic the thermal conditions during initial process development. We present a case study on one of the most studied AM alloys: Ti-6Al-4V.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Thermal Stability and Mechanical Properties of Cold-Sprayed Nickel-Yttria Coating

The microstructural evolution under the extreme environments imposed during cold spray deposition of cermet coatings and the microstructural recovery during post-processing annealing treatments is rather complex and not well understood. Here, Ni-Yttria cermet coatings on an SS304 substrate were produced using cold spray technique, resulting in a bimodal grain structure. The grain growth, phase stability, hardness, and wear properties are observed in as-deposited and annealed (at 400 °C) Ni-Yttria and pure Ni coatings. A multimodal microstructural characterization using electron microscopy, and atom probe tomography shows the structural and compositional stability of yttria particles and Ni grains. A fragmentation of Y-rich particles and dispersion in Ni was observed, however, no forced mixing/dissolution of Y in Ni is detected. Nano-yttria dispersed within the Ni grains slowed the grain growth during annealing. After annealing, Yttria reinforced coating was 1.5 times harder and showed better thermal and mechanical stability compared to the Ni coating.

Gwalani, Bharat↗
DOE OSTI2024

A Finite Difference informed Random Walk solver for simulating radiation defect evolution in polycrystalline structures with strongly inhomogeneous diffusivity

Diffusivity of species and defects on grain boundaries is usually several orders of magnitude larger than that inside grains. Such strongly inhomogeneous diffusivity requires prohibitively high computational demands for modeling microstructural evolution. Here, this paper presents a highly-efficient numerical solver, combining the Finite Difference method and Random Walk model, designed for accurately modeling strongly inhomogeneous diffusion within polycrystalline structures. The proposed solver, termed Finite Difference informed Random Walk (FDiRW), integrates a customized Finite Difference (cFD) scheme tailored for fast diffusion along thin grain boundaries represented by a single-layer of nodes. Numerical experiments demonstrate that the FDiRW solver achieves an impressive efficiency gain of 1560x compared to traditional Finite Difference methods while maintaining accuracy, making it feasible for personal computer machines to handle diffusional systems with strongly inhomogeneous diffusivity across static polycrystalline microstructures. The model has been successfully applied to simulate radiation defect evolution, showcasing its scalability to engineering scales in both length and time dimensions.

36 MATERIALS SCIENCE↗
DOE OSTI2025

4D Observations of the initiation of abnormal grain growth in commercially pure Ni

Abnormal grain growth (AGG), where a small fraction of grains grow faster than others, is critical to predict because it can significantly impact material properties. However, the mechanism behind AGG remains unclear. In this study, laboratory-based x-ray diffraction contrast tomography (LabDCT) is employed to non-destructively track the 3D microstructural evolution of high-purity nickel during the onset of AGG at 800 °C. The initial microstructure state is used to test hypothesized microstructure predictors of the initiation of AGG. The change in grain size was not related to the initial grain size or normalized integral mean curvature. Additionally, the grain boundary energy distributions of abnormal grains were indistinguishable from those of control groups exhibiting normal grain growth. However, the grains that later became abnormal exhibit large areas of asymmetric tilt boundaries that were previously found to be fast. This 3D microstructure dataset is useful to investigate new hypotheses for the initiation of AGG.

36 MATERIALS SCIENCE↗
DOE OSTI2025

AMMT 2025 Milestone

Idaho National Laboratory initiated the examination of nickel-based alloys manufactured laser powder directed energy deposition additive manufacturing for potential applications in nuclear, high temperature structural components. With the rapid push towards additive manufacturing, codes do not exist that definitively define what is or is not tolerable for each process and application, such as with conventional, wrought products. This report contains the initial work to understand possible manufacturing methods for high temperature alloys, and specifically, void formation, microstructure evolution, and mechanical properties. To generate mechanical test data, specimens were tested irrespective of voids and microstructures were analyzed to better understand how to negate/improve these issues. The preliminary results showed major decreases in mechanical performance for material tested. Test specimens will continue to be produced to further improve additive manufacturing processes, quantify void acceptance, and better understand the most suitable high temperature alloys receptive to additive manufacturing and high temperature nuclear applications.

36 - MATERIALS SCIENCE↗
DOE OSTI2021

Evolution of {delta}ferrite in a CF3 cast stainless steel upon neutron irradiation to 3, 5, 10, 20, and 40 dpa

The microstructural evolution of delta ferrite in a CF3 cast stainless steel irradiated to 3, 5, 10, 20, and 40 dpa with two dose rates was studied with atom probe tomography (APT) and transmission electron mi-croscopy. Spinodal decomposition and G-phase precipitates induced by neutron irradiation and thermal aging were quantified systematically. The neutron irradiation significantly enhances the spinodal decom-position in delta ferrite as both the spinodal wavelength (i.e. a characteristic repeat distance) and am-plitude (i.e. magnitude of elemental concentration fluctuation) increase after irradiation. The wavelength only varies slightly when the dose increases from 5 to 40 dpa, while the amplitude increases dramatically from 10 to 20 dpa and starts to saturate before 20 dpa. The dose rate and irradiation temperature also have a notable effect on the spinodal wavelength and amplitude. The study shows that higher dose rate promotes a larger wavelength at given irradiation doses. Regarding the G-phase precipitates, a slightly lower irradiation temperature would result in a smaller mean size of G-phase precipitates, while a lower irradiation dose rate would lead to a larger G-phase precipitates at a given temperature and dose. Over-all, the spinodal decomposition and G-phase precipitates in the delta ferrite continue to evolve with the increasing dose beyond 10 dpa. This study confirms that the formation of G-phase precipitates at the in-terdomain region between alpha and alpha-prime is facilitated by the Si and Mo atoms rejected from Fe rich alpha phase and the Ni and Mn atoms rejected from Cr rich alpha-prime phase. Neutron irradiation plays a dominant role in the ferrite instability, and the effect of prior thermal aging at 400 degrees C for 10,000 hours is negligible as the dose is 3 dpa and above.

duplex stainless steel↗
DOE OSTI2026

Temperature dependent interfacial microstructure in HIP-bonded Al6061/Zr joints

Pressing (HIP) at 450 °C and 560 °C under 103 MPa for 90 minutes to evaluate interfacial diffusion and microstructural evolution. Sound metallurgical bonding was achieved at both temperatures, with Zr serving as an effective diffusion barrier. Microstructural analysis revealed the the formation of a (Al,Si)3Zr intermetallic layer at the Al/Zr interface, whose thickness increased from ~100 nm at 450 °C to ~2100 nm at 560 °C, consistent with temperature-driven diffusion kinetics. The thin and continuous reaction layer observed at 450 °C indicates controlled interdiffusion and minimal reaction zone growth, favorable for maintaining interface stability and ductility. At 560 °C, enhanced atomic mobility led to pronounced intermetallic development, confirming diffusion-controlled growth behavior. These results provide valuable insights for optimizing Al/Zr interface design and diffusion barrier performance in advanced structural and energy systems.

Al/Zr interface↗
DOE OSTI2024

Microstructural stability and mechanical properties of the as-cast and heat-treated newly developed TiNbCrTa refractory complex concentrated alloy

In this study, a TiNbCrTa refractory complex concentrated alloy (RCCA) was prepared using vacuum arc remelting. The microstructural evolution and mechanical properties of both as-cast and heat-treated RCCA samples were analyzed. Heat treatment (HT) was performed at 800–1200 °C for 1 h in a vacuum-sealed environment. These samples exhibited a formation of Cr 2 Nb and Cr 2 Ti Laves phases. A variation in elemental distribution was observed, with interdendritic (ID) regions showing higher fractions of Ti and Cr, while the dendritic regions had a greater concentration of Ta and Nb. Micro-segregation at the IDs was confirmed through energy dispersive x-ray spectroscopy mapping, which inferred the formation of Cr- and Ti-rich phases during HT at 800–1200 °C. High-temperature HT at 1200 °C for 1 h led to the evolution of the hcp omega phase. Prolonged HT at 1200 °C for 96 h resulted in the evolution of a Cr-rich Laves phase (Cr 2 Ta), which was homogeneously distributed within the microstructure, indicating an unstable microstructure. Furthermore, despite prolonged HT, a variation in the elemental distribution persisted due to the presence of dendritic and ID regions. Electron backscattered diffraction analysis revealed the presence of bcc and hcp phases in the dendritic and ID regions, respectively, of the as-cast and HTed samples. The as-cast samples demonstrated a high compressive strength of approximately 2 GPa. Micro-hardness values increased with the HT temperature up to 1000 °C. Further increases under HT conditions did not significantly reduce the microhardness value, whereas prolonged HT at 1200 °C led to an increase in the microhardness value. Overall, the newly developed TiNbCrTa RCCA exhibited high-strength behavior even after the phase transformation.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Nuclear Structural Component Relevant Properties of Nickel-Based Alloys Produced via Additive Manufacturing

Idaho National Laboratory initiated examination of nickel-based alloys manufactured via three different additive manufacturing methods for potential applications in nuclear, high temperature structural components. The three methods analyzed included laser powder bed fusion, blown powder laser directed energy deposition, and wire-fed gas metal arc directed energy deposition. With the rapid push towards additive manufacturing, codes do not exist that definitively define what is or is not tolerable for each process and application, such as with conventional, wrought products. This report contains the initial work to understand possible manufacturing methods for high temperature alloys, and specifically, void formation, microstructure evolution, corrosion, and mechanical properties. To generate mechanical test data, specimens were tested irrespective of voids and microstructures were analyzed to better understand how to negate/improve these issues. The preliminary results showed major decreases in mechanical performance for material tested. Test specimens will continue to be produced to further improve each additive manufacturing processes, quantify void acceptance, and better understand the most suitable high temperature alloys receptive to additive manufacturing and high temperature nuclear applications.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Shear deformation of pure-Cu and Cu/Nb nano-laminates using micromechanical testing

Solid phase processing by introducing shear deformation into materials can result in unique microstructure evolution and enhanced mechanical properties, especially for immiscible systems such as Cu/Nb. To better understand the correlation between microstructure and deformation behavior during shear, a dedicated testing design of stress localization at predicted sites is necessary. In this study, a specialized S-shaped specimen geometry is implemented to apply localized simple-shear loading in pure-Cu and Cu/Nb accumulative roll-bonded nanolaminates. The nanoscale microstructure and proximity of interfaces in Cu/Nb offer a ~2.8-fold increase in shear stresses than pure-Cu. In pure-Cu, the plastic instability causes shear banding and an in-plane lattice rotation. In Cu/Nb, a partial bending of the interfaces occurred, resulting in a localized lattice rotation. The adapted geometry for micro-scale specimens thus successfully captures the shear deformation at predicted sites in two distinct material systems and could potentially be a powerful technique to study the deformation mechanisms.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Age hardening response of Cu-30Ni alloys: The role of Si microalloying additions

Cu-30Ni alloys offer high strength and excellent corrosion resistance for maritime applications. While primarily a solid solution system, industrial alloys typically include microalloying additions of Fe, Mn, Nb and/or Si to enable age hardening. However, an understanding of the microstructural evolution during age hardening remains incomplete. Here, we conduct systematic ageing treatments and report the resulting hardness and microstructures. The Cu-30Ni alloy with Si aged at 650 °C for 6 h demonstrates significantly enhanced Vickers hardness, reaching ∼201 HV 1 compared to 103 HV 1 for the as-homogenised sample. Si-rich clusters and γ′ precipitates are identified, with their composition, size, and volume fraction quantified to determine their strengthening contributions. First-principles atomistic simulations elucidate the underlying formation mechanisms of these clusters and precipitates, highlighting the critical role of Si in driving their nucleation and growth. This study advances the design of high-strength, Cu alloys with the potential for corrosion resistance in demanding maritime environments.

Age hardening↗
DOE OSTI2022

Damage Accumulations Predictions for Boiler Components Via Microstructurally Informed Material Models

The goal of the project was to model material behavior and degradation during cyclic plasticity— with and without hold time—for nickel-based superalloys used in USC (ultra-super-critical) and A-USC (advanced-ultra-super-critical) boiler components. The study provided physically informed models, capturing the microstructural changes taking place in the industrial components under cyclic loading and long duration stress (up to 300,000 hours) and high temperature exposure (1100°F/593°C to 1400°F/760°C). The major developments were: 1) Qualitative and quantitative understanding of microstructure evolution (gamma prime precipitates), deformation (dislocation density), and damage mechanisms of Haynes ® 282 alloy. 2) Qualitative understanding of microstructural features generating local strain variations. 3) A continuum damage mechanics model (CDM) for Haynes ® 282 alloy at 1100°F to 1400°F capturing cyclic behavior with and without hold time. 4) Structural analysis for creep and LCF life predictions of an USC thick-wall Grade 91 superheater steel header and understanding life sensitivity to wall thickness of an AUSC Haynes ® 282 header.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2024

Microstructural Coarsening Kinetics and Mechanical Property Changes in Long-Term Aged Sn–Pb–Sb Solder Joints

Tin-lead-antimony (50Sn–47Pb–3Sb wt.%) soldered assemblies were mechanically tested approximately 30 years after initial production and found to have solder joints of reduced strength. The microstructure of this solder alloy exhibits a ternary eutectic structure with Sn-rich, Pb-rich, and SnSb phases. Accelerated aging was performed to evaluate solder microstructural coarsening and associated strength of laboratory solder joints to correlate these properties to the “naturally aged” solder joints. Isothermal aging was conducted at room temperature, 55, 70, 100, and 135 °C and aging times that ranged from 0.1 to 365 days. The coarsening kinetics of the Pb-rich phase were determined through optical microscopy and image analysis methods established in previous studies on binary Sn–Pb solder. A kinetic equation was developed with time exponent n of 0.43 and activation energy of 24000 J/mol, suggesting grain boundary diffusion or other fast diffusion pathways controlling the microstructural evolution. Compression testing and Vickers microhardness showed significant strength loss within the first 20–30 days after soldering; then, the microstructure and mechanical properties changed more slowly over long periods of time. Further, by combining accelerated aging data and the microstructure-based kinetics, strength predictions were made that match well with the properties of the actual soldered assemblies naturally aged for 30 years. However, aging at the highest temperature of 135 °C produced anomalous behavior suggesting that extraneous aging mechanisms are active. Therefore, data obtained at this temperature or higher should not be used. Overall, the combined microstructural and mechanical property methods used in this study confirmed that the observed reduction in strength of ~ 30-year-old solder joints can be accounted for by the microstructural coarsening that takes place during long-term solid-state aging.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Understanding structure-processing relationships in metal additive manufacturing via featurization of microstructural images

Understanding and predicting accurate property-structure-processing relationships for additively manufactured components is important for both forward and inverse design of robust, reliable parts and assemblies. While direct mapping of process parameters to properties is sometimes plausible, it is often rendered difficult due to poor microstructural control. Exploring the direct relationship between processing conditions and microstructural features can thus provide significant physical insights and aid the overall design process. Here, in this study, we develop an automated high-throughput framework to simulate an uncertainty-aware additive manufacturing (AM) process, characterize microstructural images, and extract meaningful features/descriptors. A kinetic Monte Carlo (KMC) based model of the AM process is used to simulate microstructural evolution for a diverse set of experimentally relevant processing conditions. We perform a parametric study to explore the relationship between microstructural features and processing conditions. Our results indicate that a many-to-one mapping can exist between processing conditions and typical descriptors; therefore, multiple descriptors are thus necessary to unambiguously represent microstructural images. Our work provides crucial quantitative and qualitative in-formation that would aid in the selection of features for microstructural images. Featurized microstructures could then be utilized to build data-driven models for predictive control of microstructures and thereby properties of additively manufactured components.

36 MATERIALS SCIENCE↗
DOE OSTI2021

The subsurface structure of abraded Al–Zn–Mg–Cu alloy

Surface abrasion has been shown to introduce heavy shear stress and produce a few hundred nanometers thick altered surface layer (ASL) on Al alloys. Such ASLs exhibit microstructural changes at room temperature and different corrosion resistance than the underlying substrate. Here, we report how sample dimensions and temperature affect the deformed subsurface microstructure evolution on an abraded Al–Zn–Mg–Cu alloy using transmission electron microscopy (TEM) and atom probe tomography. The ASL microstructure evolves differently in the bulk sample than in the thin TEM specimen. In the freshly abraded ASL, the original η'/η precipitates and grain boundaries were deformed toward the abrasion direction. After 7-day natural aging of the freshly abraded bulk sample, well-defined subgrains formed locally in the ASL, and unusual Al 2 Cu (θ) and Mg x Zn y phases precipitated at the subgrain boundaries. However, during natural aging of this TEM specimen taken from the abraded and aged bulk samples, much faster changes occurred, including the continued formation of subgrains and θ particles in the entire ASL, and the diffusion of Zn atoms out of Mg x Zn y particles to form a Zn particle. On the other hand, no obvious microstructural changes occurred in the ASL during 3-month natural aging of the TEM specimen immediately taken from the freshly abraded sample. Finally, this work advances the understanding of how Al alloy microstructures respond during and following any shear deformation, and complex and unexpected effects of sample dimensions on the behavior.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Manufacturing ODS Steels from GARS Powders by Friction Consolidation and Extrusion

Previous research suggested that friction-based processing is a promising method for fabricating oxide dispersion-strengthened (ODS) steel. In this study, we combined friction consolidation and friction extrusion to successfully manufacture ODS steel rods using precursor powder made with gas atomization reaction synthesis. We examined the microstructure evolution from the initial powder to the final extruded rod, which revealed the dispersion process of Y. Additionally, by comparing the microstructures of three rods extruded at different temperatures, we showed that low-temperature friction extrusion effectively enhanced microstructure uniformity and prevented grain coarsening, leading to improved mechanical properties. Furthermore, our findings provide practical guidelines for adjusting processing parameters in the production of ODS steel using friction-based processing.

36 MATERIALS SCIENCE↗
DOE OSTI2023

An efficient instance segmentation approach for studying fission gas bubbles in irradiated metallic nuclear fuel

Abstract Gaseous fission products from nuclear fission reactions tend to form fission gas bubbles of various shapes and sizes inside nuclear fuel. The behavior of fission gas bubbles dictates nuclear fuel performances, such as fission gas release, grain growth, swelling, and fuel cladding mechanical interaction. Although mechanical understanding of the overall evolution behavior of fission gas bubbles is well known, lacking the quantitative data and high-level correlation between burnup/temperature and microstructure evolution blocks the development of predictive models and reduces the possibility of accelerating the qualification for new fuel forms. Historical characterization of fission gas bubbles in irradiated nuclear fuel relied on a simple threshold method working on low-resolution optical microscopy images. Advanced characterization of fission gas bubbles using scanning electron microscopic images reveals unprecedented details and extensive morphological data, which strains the effectiveness of conventional methods. This paper proposes a hybrid framework, based on digital image processing and deep learning models, to efficiently detect and classify fission gas bubbles from scanning electron microscopic images. The developed bubble annotation tool used a multitask deep learning network that integrates U-Net and ResNet to accomplish instance-level bubble segmentation. With limited annotated data, the model achieves a recall ratio of more than 90%, a leap forward compared to the threshold method. The model has the capability to identify fission gas bubbles with and without lanthanides to better understand the movement of lanthanide fission products and fuel cladding chemical interaction. Lastly, the deep learning model is versatile and applicable to the micro-structure segmentation of similar materials.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Salt-Mediated Coarsening in Conversion-Reaction-Synthesized Nanoporous Metals and Nanocomposites Resolved through In Situ Synchrotron Diffraction Studies

High-energy synchrotron X-rays were used to probe the structural and microstructural evolution in Fe, Co, and Cu nanoporous metals (NPMs) and metal/salt nanocomposites (NCs) produced by recently developed conversion reaction synthesis (CRS) methods. Microstructure analysis of as-synthesized samples via whole pattern fitting showed that the NPMs exhibit domain sizes that increase as Co < Fe < Cu, with both Fe and Co having crystallite sizes below 3.0 nm. The as-synthesized metal/salt NCs had similar metal sizes, and additionally, the salt in the composite had unusually large lattice microstrain whose origin is attributed to chemical substitution of metal ions into the salt (e.g., Li $1–3x$ Fe $x$ Cl for Fe 3+ ). When thermal annealing is used to modify crystallite size, pore collapse often occurs in NPMs but NCs can be effectively tuned without this problem. While the NC coarsening occurs slowly at low temperatures, it was found that there is a drastic acceleration of the reaction rate at a specific onset temperature that results in the crystallite size increasing by an order of magnitude in about a minute. Curiously, there was no evidence in the diffraction data for salt melting at this onset temperature. However, there was a sharp reduction in the salt chemical lattice strain at the onset temperature, indicating that rapid metal coarsening is facilitated by the salt. Importantly, this behavior indicates an unexpectedly coupled reaction mechanism by which the metal ions needed for grain growth are supplied by the salt in a rate-limiting fashion.

77 NANOSCIENCE AND NANOTECHNOLOGY↗