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337 records · Page 19

Additive manufacturing of a metastable high entropy alloy: Metastability engineered microstructural control via process variable driven elemental segregation

Compositional paradigm shift in high entropy alloys (HEAs) provided new opportunities for microstructural engineering, whereas process control during laser powder bed fusion (LPBF) additive manufacturing (AM) enable fine microstructure tailoring. Metastability engineering in transformation induced plasticity (TRIP) HEAs by addition of minor alloying elements is an attractive strategy for fine microstructural tuning. This study explored in detail the microstructural evolution during LPBF AM of a metastable Fe 40 Mn 20 Co 20 Cr 15 Si 5 (at.%) dual phase HEA (CS-HEA). LPBF processing window for CS-HEA was established based on quantitative analysis and experiments. Based on melt pool overlap lack of fusion pores were observed at lower energy densities (J) of $\textit{J}$ ≤ 31.25 J/mm 3 and key-hole formation by melt pool destabilization in case of $\textit{J}$ ≥ 75 J/mm 3 . The microstructure of CS-HEA consists of metastable FCC-γ and HCP-ε phases; LPBF process parameters governed the final phase fraction in the alloy which has been correlated to metastability alteration of the high temperature γ phase. Final microstructural engineering was devised by LPBF process control which enabled cooling rate manipulation to guide Mn and Si segregation at the cell boundaries, thereby controlling the matrix metastability and final phase fraction. Additionally, high resolution transmission electron microscopy (TEM) revealed disparity in stacking fault morphology in CS-HEA with LPBF process variable alterations associated with local variations in chemical composition and stacking fault energy. Further, the phase evolution with process parameters also affected the nanomechanical behavior of the alloy.

36 MATERIALS SCIENCE↗

Schmid factor crack propagation and tracking crystallographic texture markers of microstructural condition in direct energy deposition additive manufacturing of Ti-6Al-4V

Metallic additive manufacturing (AM) provides a customizable and tailorable manufacturing process for new engineering designs and technologies. The greatest challenge currently facing metallic AM is maintaining control of microstructural evolution during solidification and any solid state phase transformations during the build process. Ti-6Al-4V has been extensively surveyed in this regard, with the potential solid state and solidification microstructures explored at length. In this study, we evaluate the applicability of previously determined crystallo- graphic markers of microstructural condition observed in electron beam melting powder bed fusion (PBF-EB) builds of Ti-6Al-4V in a directed energy deposition (DED) build process. The aim of this effort is to elucidate whether or not these specific crystallographic textures are useful tools for indicating microstructural conditions in AM variants beyond PBF-EB. Parent β-Ti grain size was determined to be directly related to α-Ti textures in the DED build process, and the solid state microstructural condition could be inferred from the intensity of specific α-Ti orientations. Qualitative trends on the as-solidified β-Ti grain size were also determined to be related to the presence of a fiber texture, and proposed as a marker for as-solidified grain size in any cubic metal melted by AM. Analysis of the DED Ti-6Al-4V build also demonstrated a near complete fracture of the build volume, suspected to originate from accumulated thermal stresses in the solid state. Crack propagation was found to only appreciably occur in regions of slow cooling with large α +β colonies. Schmid factors for the basal and prismatic α-Ti systems explained the observed crack pathway, including slower bifurcation in colonies with lower Schmid factors of both slip systems. Colony morphologies and localized equiaxed β-Ti solidification were also found to originate from build pauses during production and uneven heating of the build edges during deposition. Tailoring of DED Ti-6Al-4V microstructures with the insight gained here is proposed, along with cautionary insight on preventing unplanned build pauses to maintain an informed and controlled thermal environment for microstructural control.

36 MATERIALS SCIENCE↗

Uncovering grain and subgrain microstructure at the scale of additive manufacturing melt tracks with a scalable cellular automaton solidification model

Metal additive manufacturing, characterized by rapid solidification, yields refined grains with a distinctive cellular subgrain microstructure that plays a pivotal role in determining material properties. Due to the significant computational expense demanded to simulate the required physics with submicron spatial resolution, their numerical simulations have been limited to proof-of-concept studies to either 2D or small subregions of a melt pool. In this study, an open-source, scalable, solidification code, muMatScale, based on the cellular automaton method, has been developed to predict the grain and the underlying subgrain microstructure over an entire melt pool. The model incorporates flexible parallelization schemes, utilizing MPI and OpenMP GPU Offloading, in addition to appropriate multi-physics specific to non-equilibrium rapid solidification in AM. The impact of nucleation parameters on grain microstructures was investigated with a focus on grain size variations and morphology transitions. With selected nucleation parameters, the simulation predicted the grain size, subgrain morphology, crystallographic orientation, and microsegregation aligned with experimental measurements. The model demonstrates that epitaxial grain growth is a dominant factor at the melt pool boundary, influencing grain size variation under different grain sizes in the build plate while maintaining consistent primary dendrite arm spacing under identical thermal conditions. Here, the highly efficient numerical model enables large-scale simulations with a spatial resolution of 100 nm or less, unveiling unprecedented insights into thermal and solutal diffusion driven grain growth, and the subgrains with microsegregation within grains in 3D across scales. muMatScale will enable the linking of submicron length-scale microstructure to part-level material behavior by investigating fundamental solidification problems at the intercellular scale in many-track and many-layer builds.

36 MATERIALS SCIENCE↗

Degradation science: Integrating modeling and experiments to predict localized corrosion processes (Annual Progress Report)

Additively manufactured (AM) eutectic high-entropy alloys (EHEAs), such as nano-lamellar AlCoCrFeNi 2.1 , have excellent strength, ductility, and wear resistance even at elevated temperatures, but their corrosion behavior in aggressive acids at different length scales remain poorly understood. This work investigates the corrosion behavior of laser powder bed–fused (L-PBF) AlCoCrFeNi 2.1 as a function of annealing temperatures, probing degradation mechanisms from nanoscopic to macroscopic length scales. The alloy is dual phase consisting of a ductile FCC L1 2 phase and a high-strength BCC B2 phase. Rapid solidification during L-PBF produces a far-from-equilibrium nano-lamellar structure with nearly homogeneous elemental distribution, which tends to evolve upon annealing toward Cr/Co/Fe-enriched FCC and Al/Ni-enriched B2. Three conditions were studied: as-printed, 600 °C/5 h, and 1000 °C/1 h, over which B2 lamellae coarsen, lamellar spacing increases, and elemental segregation becomes more prominent. Microstructure and chemistry were characterized by scanning electron microscopy (SEM) and energy-dispersive spectroscopy (EDS), while in-situ electrochemical atomic force microscopy (EC-AFM) was used to link early (<5 h) local dissolution to microstructure after exposure in sulfuric acid. EC-AFM highlights preferential dissolution of the BCC/B2 phase where the surrounding matrix is Cr-depleted and directly quantifies the dissolution rates within individual phases, tracks the transition from early nano-scale attack to partial repassivation, to correlate height differences with current and impedance responses. To monitor longer-term behavior (up to 96 h), ex-situ AFM, SEM, and confocal imaging were combined with conventional bulk electrochemical tests, bridging nanoscale observations to micro/meso-scale damage morphologies. At the meso-scale, the deepest dissolution channels align with the build-direction lamellae and melt-pool boundaries, indicating that printing directionality guides the propagation of these localized corrosion sites. Annealing modifies corrosion by restructuring BCC/FCC phase fractions, lamellar spacing, and Cr/Al segregation, thereby changing the cathode/anode ratio and passive film stability. The results clarify how as-printed and annealed nano-lamellar architectures differ in their susceptibility to selective dissolution; how elemental segregation competes with residual stresses along the build direction. With these insights, future work will use CALPHAD-guided alloy modification to stabilize higher Cr contents in the B2 phase while retaining a dominant FCC+B2/BCC microstructure, with the goal of designing mechanically robust, corrosion-resistant EHEAs for safety-critical applications to leverage the LLNL’s broader national and global security mission.

36 MATERIALS SCIENCE↗

Directed energy deposition of Haynes 282 nickel superalloy

Laser powder directed energy deposition was employed to fabricate Haynes® 282 Ni-based superalloy for high temperature creep testing. Material was heat treated using a single-step aging heat treatment of 800 °C for 4 h. Microstructural analysis was conducted in the as-deposited, solution-annealed, and age-hardened conditions. γ′ precipitates were absent in the as-deposited and annealed condition but formed during aging with an average size of 48.5 ± 12 nm. γ’ denuded zones ranging in thickness from 73 to 469 nm were observed adjacent to an effectively continuous grain boundary carbide film that covered 72.5% of the measured boundary length. The heat-treated material contained a high-volume fraction of TiC carbides ranging in size from 38 to 457 nm. Electron backscatter diffraction showed partial recrystallization, with 77-83% recrystallized area and a heterogeneous grain-size distribution. Creep testing at 750 °C at 300, 320, and 350 MPa revealed significantly inferior performance compared to wrought material, with higher strain rates, earlier tertiary onset, and shorter rupture lives. Fractography shows that failure was dominated by intergranular rupture. Post rupture microstructural analysis results suggest that the creep behavior was primarily governed by the non-equilibrium interface network rather than the bulk γ/γ’ matrix. In conclusion, the findings indicate that achieving wrought-like creep performance necessitates substantial improvements in the additive process, specifically focusing on enhanced homogenization, full recrystallization, and precise control over the morphology and distribution of carbides.

36 - MATERIALS SCIENCE↗

Missile impact craters (White Sands Missile Range, New Mexico) and applications to lunar research: Contributions to astrogeology

Craters in natural materials at White Sands Missile Range, N. Mex., were produced by the impact of high-velocity to hypervelocity missiles traveling along oblique trajectories with kinetic energies between 2.1 and 81 × 1014 ergs. The oblique impacts produce craters 2 to 10 m across with morphologies and ejecta that are bilaterally symmetrical with respect to the plane of the missile trajectory. Rims are high and the amount of ejecta large in down-trajectory and lateral directions, whereas rims are low to nonexistent and ejecta thin to absent up-trajectory. Symmetry development and modifications of the symmetry are a function of target material, local topography, and angle of impact. Seven mappable units can be recognized in and around the craters. Three of these are ejecta: thick ejecta near the crater, thin to discontinuous ejecta at greater distances, and scattered ejecta at the greatest distances to the limit of throwout. These ejecta units may be absent on the up-trajectory side; if present, they are rarely as thick or continuous as on other sides of the crater. Three units are target materials: undeformed target material exposed in local patches through thin to discontinuous ejecta and everywhere between the fragments of scattered ejecta, tilted and broken target material exposed in upper crater walls, and shattered and fractured target material exposed on the up-trajectory crater wall. The seventh unit is slope material composed of talus and fallback within the crater. Development, character, and exposure of these units varies chiefly with the target material. Ejecta from the craters is chiefly broken but relatively undeformed target material that may range in size from very fine grained debris to large blocks. Where the target is porous, significant amounts of the ejecta are composed of sheared and compressed fragments, some coated with dark layers of mixed projectile pieces, powder, and fused metal mixed with crushed target material. For layered targets, the original stratigraphic sequence is crudely preserved and in inverted order in thick ejecta. Secondary impact craters are produced by the impact of ejected fragments when the surrounding surface materials are sufficiently weak. A wide variety of secondary impact crater relations may result. Secondary craters nearest the primary crater have blocks in them that are larger than or the same size as the crater they produced. Farther from the primary crater, the fragments are generally smaller than the secondary crater and are ejected from it. Excavation of four craters revealed a mixed breccia beneath the crater floor composed of missile pieces, sheared and compressed target material, and crushed debris. Banded, disaggregated target material and nonmixed breccia surrounded the mixed breccia, and these breccias were surrounded by a zone of conjugate fractures. Beneath the ejecta on the lateral and down-trajectory crater flanks, the target materials were tilted upward and broken. Up-trajectory, open fractures and downward displacement occurred in two of the craters. No displacement was observed for the other two. Beneath the down-trajectory rims of craters with distinct layering, overturned synclines were observed. Missile breakup and behavior during cratering are a function of target and missile properties. Missile breakup depends on missile velocity and is most extensive at high velocities, where the missile is fragmented, powdered, and partly fused. Burial of missile or its fragmented, powdered, and fused remains is greatest for porous targets and least for dense cohesive targets. For very porous targets, camouflet structures containing the fragmented missile may form. Least squares fit to the data on craters in dry to moist targets indicate V(a) = 10^(-11.433)E(p)^(1.205) where V(a) is the volume of the apparent crater and E(p) is the kinetic energy of the missile. This equation is consistent with expectations of the equations relating apparent depth and radius to kinetic energy. Extrapolation of displaced masses and kinetic energies for laboratory impacts with sand and rock converge near 10^(15) to 10^(16) ergs, where the extrapolations are near the data on missile impact craters, corrected for impact angle. Displaced masses of craters produced by missile impacts and by chemical explosives with small scaled depths of burial are about the same when the kinetic energies of the missiles (corrected for angle of impact) are equal to the TNT equivalent energy of the explosive. The problem of equivalent scaled depth of burst for an impact crater is complicated and not entirely resolved, however. Both missile impact craters and chemical explosive craters in water-saturated targets are larger than their counterparts in dry to moist materials. Data collected during the study of missile impact craters have helped resolve a number of problems in lunar research: (1) the soillike nature of lunar surface materials was predicted, (2) sizes of craters produced by artificial impacts were correctly predicted, (3) certain features imaged by Surveyor were found to be analogous to features associated with missile impact craters, {4) missile impacts were used in support of the Apollo passive seismic experiment, (5) craters seen in Apollo orbital photographs were found to be similar to some missile impact craters, (6) missile impact craters supplied data on sample collection and crater phenomenology used in training astronauts, and (7) some returned lunar samples are similar to coated, sheared, and compressed fragments ejected from missile impact craters.

H. J. Moore↗

Molten Salt Corrosion Tests of Additively Manufactured Stainless Steel 316H

Molten salt reactors (MSRs) have drawn considerable interest due to their favorable safety features, high thermal efficiency, and compatibility with different fuel cycles. Yet, the success of MSRs hinges critically on the performance of structural materials to be used in these aggressive molten salt environments, where corrosion and material compatibility remain primary challenges to long-term reliability. Additively manufactured (AM) nuclear structural materials prompt the use of novel geometries and compositions to enhance material performance and reduce costs of constructing MSRs. The rapid solidification conditions inherent to AM processing impart distinctive microstructural features, including cellular sub-structures, dislocation densities, residual stress, and oxide inclusions, which can influence material performance in MSR components. While the mechanical properties of AM stainless steels have been widely studied, their corrosion behavior, particularly in molten salt environments, has received far less attention. Addressing these needs, the Advanced Materials and Manufacturing Technologies (AMMT) program provides a framework for systematically evaluating how unique microstructures produced by AM processes influence the performance of these materials in these demanding environments and for developing reproducible testing workflows that can support future code qualification efforts and standards development. Bridging this knowledge gap is essential for assessing the viability of AM alloys in MSRs and informing qualification strategies. A further challenge is the absence of standardized protocols for molten salt corrosion testing. Accordingly, this report provides an account of the corrosion evaluation of AM 316H stainless steel in NaCl 2 -MgCl 2 molten salt at 550 °C, with exposure times of 100 and 500 hours. It documents the experimental procedures implemented under the AMMT program, including salt preparation, exposure protocols, and post-test characterization methods, to establish reproducibility and transparency. Importantly, the study examines AM 316H samples in the as-fabricated condition, directly reflecting the surface state most relevant to engineering applications, and compares their behavior to machine-cut surfaces. Overall, preliminary evaluations have noted that surface conditions (e.g. morphology, contamination, etc.) have a noticeable impact on the corrosion resiliency. The impact of the corrosion is difficult to detect at 100h, unless, in the case of AM 316H, the specimen surface is decontaminated. After 500 h, as-fabricated surfaces of AM and wrought 316H display evidence of general versus preferential corrosion attack, respectively. Both AM and wrought 316H machine-cut surfaces exhibit a continuous Cr depletion zone, evident of general corrosion. While the estimated extent of corrosion appears within the same order of magnitude regardless of the surface condition, it is apparent that more predictable behavior is observed on machine-cut surfaces. Nonetheless, further investigation is necessary to fully elucidate the corrosion mechanism under these conditions.

36 - MATERIALS SCIENCE↗

DISTRIBUTION OF ION-EXCHANGEABLE RARE EARTH ELEMENTS AND CRITICAL MINERALS IN COAL-HOSTED CLAYS OF THE POWDER RIVER BASIN, WY

Increasing demand for a more robust domestic supply of rare earth elements (REE) and critical minerals (CM) has led to significant investigation into unconventional sources. Coal and coal byproducts from the Powder River Basin (PRB) of Wyoming are potential sources of REE but lack complete characterization of mineral hosts including ion-adsorption clays (IACs). IACs, which provide a substantial portion of the global REE supply, form when hydrated REE complexes are physiosorbed to negatively charged sites on clay surfaces. Typical IAC minerals include kaolinite, illite, and smectite. REE complexes are easily leached from IACs via ion exchange, making them economically attractive. However, research regarding the partitioning behaviors of strategic metals into PRB coal-hosted clays is limited. This project aims to quantify the modes of occurrence and distribution of REE and CM in clay minerals derived from PRB coals. Strategic metals investigated in this project have historic production or promising deposits within the PRB and/or high anticipated supply risk, and include: REE (lanthanides and Y), V, Ti, platinum group elements (PGE; Pt, Pd, Rh, Ru, Ir, Os), Al, Co, Ga, Zr, and W. Semi-quantitative compositional data from portable x-ray fluorescence spectroscopy (pXRF) on coal core from the PRB is consistent with the known correlation between REE and Al content, suggesting increased REE abundance will be found in clay-rich units. pXRF data also identifies elevated V, Ti, Co, and Zr correlated with Al. Preliminary x-ray diffraction (XRD) data indicates kaolinite, illite, and dickite are abundant minerals in overburden and clay-rich partings. Quantitative analysis via inductively coupled plasma mass spectrometry (ICP-MS) provides insights into REE and CM fractionation in coals as we compare trace metal occurrence to variations in mineralogy. Additionally, we apply scanning electron microscopy (SEM) and energy dispersive x-ray spectroscopy (EDS) data to correlate clay size and morphology to trace metal occurrence. Our findings supplement a broader effort to couple REE and CM extraction with existing domestic coal production and contribute to the fundamental understanding of adsorption processes that occur in low-temperature basin environments.

Stuart, Sophia↗

Simulated meteorite impacts and volcanic explosions: Ejecta analyses and planetary implications

Past cratering studies have focused primarily on crater morphology. However, important questions remain about the nature of crater deposits. Phenomena that need to be studied include the distribution of shock effects in crater deposits and crater walls; the origin of mono- and polymict breccia; differences between local and distal ejecta; deformation induced by explosive volcanism; and the production of unshocked, high-speed ejecta that could form the lunar and martian meteorites found on the Earth. To study these phenomena, one must characterize ejecta and crater wall materials from impacts produced under controlled conditions. New efforts at LLNL simulate impacts and volcanism and study resultant deformation. All experiments use the two-stage light-gas gun facility at LLNL to accelerate projectiles to velocities of 0.2 to 4.3 km/s, including shock pressures of 0.9 to 50 GPa. We use granite targets and novel experimental geometries to unravel cratering processes in crystalline rocks. We have thus far conducted three types of simulations: soft recovery of ejecta, 'frozen crater' experiments, and an 'artificial volcano. Our ejecta recovery experiments produced a useful separation of impactites. Material originally below the projectile remained trapped there, embedded in the soft metal of the flyer plate. In contrast, material directly adjacent to the projectile was jetted away from the impact, producing an ejecta cone that was trapped in the foam recovery fixture. We find that a significant component of crater ejecta shows no signs of strong shock; this material comes from the near-surface 'interference zone' surrounding the impact site. This phenomenon explains the existence of unshocked meteorites on the Earth of lunar and martian origin. Impact of a large bolide on neighboring planets will produce high-speed, weakly shocked ejecta, which may be trapped by the Earth's gravitational field. 'Frozen crater' experiments show that the interference zone is highly localized; indeed, disaggregation does not extend beyond approx. 1.5 crater radii. A cone-shaped region extending downward from the impact site is completely disaggregated, including powdered rock that escaped into the projectile tube. Petrographic analysis of crater ejecta and wall material will be presented. Finally, study of ejecta from 0.9- and 1.3-GPa simulations of volcanic explosions reveal a complete lack of shock metamorphism. The ejecta shows no evidence of PDF's, amorphization, high-pressure phases, or mosaicism. Instead, all deformation was brittle, with fractures irregular (not planar) and most intergranular. The extent of fracturing was remarkable, with the entire sample reduced to fragments of gravel size and smaller.

Gratz, A. J.↗

Lunar and Planetary Science XXXV: Missions and Instruments: Hopes and Hope Fulfilled

The titles in this section include: 1) Mars Global Surveyor Mars Orbiter Camera in the Extended Mission: The MOC Toolkit; 2) Mars Odyssey THEMIS-VIS Calibration; 3) Early Science Operations and Results from the ESA Mars Express Mission: Focus on Imaging and Spectral Mapping; 4) The Mars Express/NASA Project at JPL; 5) Beagle 2: Mission to Mars - Current Status; 6) The Beagle 2 Microscope; 7) Mars Environmental Chamber for Dynamic Dust Deposition and Statics Analysis; 8) Locating Targets for CRISM Based on Surface Morphology and Interpretation of THEMIS Data; 9) The Phoenix Mission to Mars; 10) First Studies of Possible Landing Sites for the Phoenix Mars Scout Mission Using the BMST; 11) The 2009 Mars Telecommunications Orbiter; 12) The Aurora Exploration Program - The ExoMars Mission; 13) Electron-induced Luminescence and X-Ray Spectrometer (ELXS) System Development; 14) Remote-Raman and Micro-Raman Studies of Solid CO2, CH4, Gas Hydrates and Ice; 15) The Compact Microimaging Spectrometer (CMIS): A New Tool for In-Situ Planetary Science; 16) Preliminary Results of a New Type of Surface Property Measurement Ideal for a Future Mars Rover Mission; 17) Electrodynamic Dust Shield for Solar Panels on Mars; 18) Sensor Web for Spatio-Temporal Monitoring of a Hydrological Environment; 19) Field Testing of an In-Situ Neutron Spectrometer for Planetary Exploration: First Results; 20) A Miniature Solid-State Spectrometer for Space Applications - Field Tests; 21) Application of Laser Induced Breakdown Spectroscopy (LIBS) to Mars Polar Exploration: LIBS Analysis of Water Ice and Water Ice/Soil Mixtures; 22) LIBS Analysis of Geological Samples at Low Pressures: Application to Mars, the Moon, and Asteroids; 23) In-Situ 1-D and 2-D Mapping of Soil Core and Rock Samples Using the LIBS Long Spark; 24) Rocks Analysis at Stand Off Distance by LIBS in Martian Conditions; 25) Evaluation of a Compact Spectrograph/Detection System for a LIBS Instrument for In-Situ and Stand-Off Detection; 26) Analysis of Organic Compounds in Mars Analog Samples; 27) Report of the Organic Contamination Science Steering Group; 28) The Water-Wheel IR (WIR) - A Contact Survey Experiment for Water and Carbonates on Mars; 29) Mid-IR Fiber Optic Probe for In Situ Water Detection and Characterization; 30) Effects of Subsurface Sampling & Processing on Martian Simulant Containing Varying Quantities of Water; 31) The Subsurface Ice Probe (SIPR): A Low-Power Thermal Probe for the Martian Polar Layered Deposits; 32) Deploying Ground Penetrating Radar in Planetary Analog Sites to Evaluate Potential Instrument Capabilities on Future Mars Missions; 33) Evaluation of Rock Powdering Methods to Obtain Fine-grained Samples for CHEMIN, a Combined XRD/XRF Instrument; 34) Novel Sample-handling Approach for XRD Analysis with Minimal Sample Preparation; 35) A New Celestial Navigation Method for Mars Landers; 36) Mars Mineral Spectroscopy Web Site: A Resource for Remote Planetary Spectroscopy.

Source record↗

Plasticity and Damage Modeling of Stress Asymmetry and Dynamic Behavior of AFS Additive Manufactured Aluminum Alloy 2219

The Solid State Additive Manufacturing (AM) process referred as MELD that fabricated the samples in this study, provides a new path for repairing, coating, joining and additive manufacturing metals and metal matrix composites. This research will be the first application of a physics-based microstructure dependent internal state variable (ISV) plasticity and damage material model to capture the mechanical response of an AM Aluminum Alloy (AA) 2219 via the MELD process. In this research, a microstructure-based internal state variable (ISV) plasticity-damage model was used to capture the mechanical behavior of AFS 2219 aluminum alloy. Aeroprobe Corporation, creator and patent holder for the MELD process, fabricated the material by pushing a solid filler rod of AA2219-T861 material through a hollow rotating tool onto an AA2219 T851 plate substrate. As feedstock, solid or powder precursor metals are pushed through a nonconsumable rotating cylindrical tool. Herein, added layers are deposited and metallurgically bonded to substrate material or previously deposited layers by the heat generated from the rotating tool through plastic deformation of the filler material. Once a layer has been added, the tool height increases, and starts the deposition of the next layer. This process results in beneficial properties such as grain refinement, homogenization and reduced porosity (fully dense). This process will experience temperatures similar to those in the weld nugget zone (WNZ) in friction stir welding (FSW), ranging from 0.6-0.9 Tm, with Tm being the melting point of the material. MELD is highly scalable with AA deposition rates reaching over 1000 cm3/hr, which allows for MELD being used for repairs, coatings, and building components. A motivating factor driving the research for physics-based history dependent material modeling of MELD components is the ability to accurately capture the stress-state and strain rate dependence in the material caused by variations in material microstructure from the MELD processing of new or repaired components. The ISV model incorporates microstructural content and is consistent with continuum level kinematics, kinetics, and thermodynamics. These features allow the ISV model to capture large deformations at the structural scale using the kinematic and isotropic hardening, while microscale damage is obtained from the microstructural features. The benefits of the ISV model arise from the inclusion of structure-property relationships identified from microstructural characterization and experimentation. The Bauschinger effect (BE) is an important concept, vital in the accurate prediction of cyclic stress-strain response of ductile materials such as metals. The ISV model has been successfully used to capture the behavior and damage, and the BE of different aluminum alloys and steels. The ISV model uses kinematic and isotropic hardening to help capture deformations of the material at the macro scale. To understand this hardening relationship, calculating the kinematic and isotropic hardening relationship in the material is warranted for a high-fidelity model. Electron Backscattered Diffraction (EBSD) was used to characterize the as-fabricated microstructure, where a fully-dense equiaxed grain morphology with average grain size of 2.5 μm was observed. Microhardness mapping of the as-built structures, monotonic tension and compression experiments at both quasi-static (0.001/s) strain rates, tension-followed-by-compression and compression-followed-by-tension experiments were performed to obtain the set of plasticity and damage constants necessary to capture strain rate and stress state behavior of this additive material. To calibrate the plasticity-damage model, a single set of constants were determined to capture the different stress states the MELD AA2219. One set of the constants was determined from experimental true stress-strain curves for the tension and compression data. Additionally, microstructural information and data from the open literature were used as the other model constants. This research is a first of its kind for AFS AA2219, includes correlating the ISV model to the monotonic experimental results that capture the isotropic and kinematic plasticity mechanical response.

Rivera, O. G.↗

Mineralogical, Elemental, and Tomographic Reconnaissance Investigation for CLPS (METRIC): A Payload Designed for Exploration of Terrestrial Planetary Bodies

Geological materials (indeed, all solid objects) are characterized by their crystal structure, elemental composition, and morphology. The Mineralogical, Elemental, and Tomographic Reconnaissance Investigation for CLPS (METRIC) instrument suite quantifies all three. These measurements address fundamental science questions (e.g., the origin and evolution of planetary bodies) and support the human exploration of space (e.g., the characterization of regolith for ISRU and the constraint of its geotechnical properties). METRIC comprises an X-ray Diffraction/X-ray Fluorescence instrument (XRD: mineral structure and XRF: elemental composition), an X-ray micro-Computed Tomography instrument (XCT: 3D internal micromorphology), and a hyperspectral imaging infrared spectrometer (IRS) to provide local/regional mineralogic context for these measurements. METRIC XRD/F draws heritage from the highly successful Mars Science Laboratory CheMin instrument. The METRIC XRD/F employs two separate sample cells, one optimized for XRD and one for XRF, resulting in more rapid XRD analysis (tens of minutes vs. tens of hours for CheMin) and an orders-of-magnitude improvement in XRF detection. XCT has not been deployed in space, so the METRIC XCT represents a new capability for solar system exploration. The XCT uses the same basic high-TRL components as METRIC XRD/F, decreasing its development cost for flight. The METRIC IRS is a derivative of the NASA Earth Science Technology Office funded Hyperspectral Thermal Imager instrument and utilizes the NASA Technology Transfer Program to incorporate a commercial-of-the-shelf infrared camera ruggedized for space by NASA Marshall Space Flight Center. The IRS spectral range (8–14 µm) and resolution (10.8 cm -1 ) are tailored to quantify mineralogy in rocks using their characteristic Reststrahlen bands and to characterize mineralogy of soils using the position of the Christensen Feature. The METRIC payload is currently designed for deployment to the Moon on a Commercial Lunar Payload Services (CLPS) mission, where the XRD/F and XCT would be located on a lander and the IRS would be on deployed on a companion rover to evaluate the mineralogical diversity of the landing site. A pneumatic drill designed by Honeybee Robotics would excavate regolith up to 50 cm below the lander and deliver multiple aliquots of regolith to the XRD/F and XCT. The METRIC payload could also be deployed on a rover. In this case, a sample handling system on a robotic arm could scoop regolith and/or drill rocks and deliver powder to the XRD/F and XCT located in the rover’s interior. Alternatively, METRIC instruments could be used singly or in combination on human space missions. The XRD/F and XCT could be used to characterize samples in a rover or in a science laboratory within a habitat. These data could help astronauts identify resource-enriched rocks and regolith and triage geologic samples to return samples of high interest for analysis in terrestrial laboratories. The IRS could be attached to a human-navigated rover to collect mineralogical data along a traverse and identify high-priority science samples.

E. B. Rampe↗

Compatibility of molten plutonium with wrought and additively manufactured metal crucibles

Understanding plutonium’s interaction with metals is crucial for optimizing pyrochemical operations, nuclear fuel containment, and various actinide processing techniques. Traditionally, tantalum crucibles are employed for plutonium processing due to their high durability, excellent temperature stability, and low solubility in plutonium. However, tantalum faces challenges such as plutonium wetting and diffusion, making surface coatings particularly important for crucibles in pyrochemical applications to enhance corrosion resistance against plutonium. Tantalum is also expensive and difficult to machine, prompting the need for advanced manufacturing techniques to address these challenges. Here, in this work, we investigate the interaction of Pu with tantalum and titanium crucibles fabricated using both traditional machining methods and laser powder bed fusion (LPBF) additive manufacturing (AM). LPBF-AM is an advanced technique that allows for the creation of complex geometries from traditionally difficult-to-machine metals by using a high-powered laser to build parts. Previous studies of conventional manufactured tantalum have utilized oxidation and carburization of the surface to mitigate plutonium wetting; however, no studies of surface modified LPBF-AM material have been undertaken. These studies are crucial, given the typical differences in the grain structure between conventional and LPBF-AM materials. All crucibles underwent differential scanning calorimetry to confirm the melting of plutonium. Subsequently, the crucibles were sectioned and mounted in epoxy for microstructural analysis using optical microscopy and scanning electron microscopy. This investigation, comparing the performance of wrought vs AM metal crucibles, provides a basis for future tooling applications in actinide processing techniques and can address the challenges associated with traditional machining, particularly in pyrochemical applications.

Actinides↗