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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 343 records · Page 19

Reflectivity Control Device (RCD) Roll Momentum Management for Solar Cruiser and Beyond

Reflectivity control devices (RCDs), thin film optical devices that are actuated (by application of a voltage across the device) to control the reflection of sunlight on their surfaces, can effectively enable roll momentum management (MM) of a solar sail operating in deep space, outside any magnetic field. This enables solar sails to maintain adequate attitude control in these challenging environments without sacrificing mission life by using expendables. They were planned and developed for use on Solar Cruiser, operating sunward of the Sun-Earth Lagrange Point 1 (sub-L1) in a propulsion-intensive artificial halo orbit. Located in pairs of panels near the distal end of each of four booms, each articulated at a slight angle out of the sail plane to produce a force tangent to the sail at a large moment arm, the RCDs provide roll torque capabilities by using simple switching logic to determine which panels should be activated (voltage applied) to produce torque in the desired direction. The performance capabilities and constraints of these devices across a range of operating conditions, namely sun-relative attitude, is well characterized, granting designers insight on how to properly size the system and optimize the system and component designs to maximize roll torque per unit area. With an informed design, RCDs can be very effective actuators for managing roll momentum with minimal detrimental system impacts (mass, power, complexity, etc.) on Solar Cruiser and other future deep space solar sail missions.

Andrew F Heaton↗

Rolling Horizon with K-Position Search Method for Strategic Deconfliction of Package Delivery UAS

This research focuses on the strategic deconfliction of unmanned aircraft systems (UAS) in an urban package delivery environment with two depots and multiple drop-off locations. Since the formulated mixed-integer nonlinear programming (MINLP) problem is non-deterministic polynomial-time (NP) hard, a heuristic algorithm called "rolling horizon with k-position search (KPS)" is used to compute the departure sequence and scheduled time of departure (STD) of each UAS at a depot, considering temporal constraints at en-route crossing waypoints and depots for strategic deconfliction. The simulation studies show that an increase in the value of k (local neighborhood search) in the KPS reduces the average ground delay at the cost of an increase in the computation time for a given number of UAS, size of the rolling horizon window, and number of depots involved in the local neighborhood search. The studies also show that for a given rolling horizon window, the computation time increases exponentially with an increase in the total number of UAS flights when serial processing the local neighborhood search of KPS (with k > 1) and drops by an order of magnitude upon performing the local neighborhood search of KPS using parallel processing instead of serial processing. The computation time drops with the reduction in air traffic complexity of a scenario for a given number of flights, k (local neighborhood search), and rolling horizon window.

UTM↗

Oscillations in the Mechatronic System of a Multi-Stand Rolling Mill

The mechatronic system of the DUO-300 rolling mill is analyzed. The influence of the roller’s linear velocity on the distribution of frictional forces in the rolling region is studied. A nonlinear relation is found between the load and the roller speed. The conditions of self-oscillation in rolling are determined. Methods of damping the self-oscillation are considered.

42 ENGINEERING↗

A Comprehensive Analysis of Macrosegregation Formation During Twin-Roll Casting

A two-phase Eulerian–Eulerian volume-averaged model is used to predict the formation of macrosegregation during the twin-roll casting of inoculated Al-4 wt pct Cu alloys. For low solid fractions, the equiaxed crystals are modeled according to the submerged object approach. However, above a given transition limit, they are assumed to behave like a viscoplastic material. This means that the solid phase behaves as a coherent structure that can influence the motion of the liquid. Such approach allows one to take into account the flow dynamics arising from the occurrence of both solidification and hot rolling simultaneously, which usually occurs in twin-roll casting. Therefore, it is possible to explain the origin of the macrosegregation patterns obtained in the simulations based on the relative motion between the phases. Compression-induced expulsion of segregated melt is observed as a result of the deformation of the solidifying shells. Such occurrence leads to a negative macrosegregation region in the outer part of the as-cast strip. Then, because the solute-enriched melt is squeezed out toward adjacent regions, two positively segregated bands can be found near the center of the domain. Furthermore, it is shown how solidification-induced feeding weakens the absolute value of the negative and positive segregation bands.

36 MATERIALS SCIENCE↗

High Strength, Utilizable Ductility and Electrical Conductivity in Cold Rolled Sheets of Cu-Cr-Zr-Ti Alloy

The microstructure and properties of Cu-0.5Cr-0.03Zr-0.04Ti (wt.%) alloy subjected to cold rolling and aging were investigated using hardness and electrical conductivity measurement, tensile testing, and transmission electron microscopy. Plates subjected to 85% reduction in thickness showed significant improvement in the strength compared to solution treated and aged condition. By proper selection of aging temperature, ductility could be significantly improved without reduction in the strength. Aging of the cold rolled sheet at 420 °C for 1 h yielded an ultimate tensile strength and yield strength of 540 and 460 MPa, respectively. On the other hand, total and uniform elongation was 16 and 12%, respectively, with an electrical conductivity of 65 %IACS. The combination of properties achieved after cold rolling and aging is attributed to the higher dislocation density, ultrafine grains and nano-sized chromium precipitates.

36 MATERIALS SCIENCE↗

Microstructural and Mechanical Properties of Hot Roll Bonded Titanium Alloy/Low Carbon Steel Plate

In this paper, a titanium alloy and low carbon steel were bonded via hot rolling in a vacuum, and the effect of roll bonding temperature and reduction ratio on the microstructural and mechanical properties of the plate was studied. When the bonding temperature was between 850 and 1050 °C, the shear strength of the interface increased with an increasing reduction ratio from 18 to 70%. At a bonding temperature of 950 °C and at a rolling reduction ratio of 70%, the best bonding strength was obtained, and a shear fracture occurred on the low carbon steel matrix. At 1050 °C, brittle compounds, i.e., TiC, FeTi, and Fe{sub 2}Ti, formed at the interface, which decreased the bonding strength. The large reduction ratio can break up compounds at the interface and extrude fresh metal for bonding, thereby increasing the bonding strength.

36 MATERIALS SCIENCE↗

Effects of Synchronous Rolling on Microstructure, Hardness, and Wear Resistance of Laser Multilayer Cladding

A synchronous rolling method was proposed to assist laser multilayer cladding, and the effects of this method on microstructure, microhardness, and wear resistance were studied. Results show that the microstructure and mechanical properties of the traditional cladding layer exhibit periodic inhomogeneity. Synchronous rolling breaks the columnar dendrite crystals to improve the uniformity of the organization, and the residual plastic energy promotes the precipitation of strengthening phases, as CrB, M{sub 7}C{sub 3}, etc. The hardness and wear resistance of the extruded cladding layer increase significantly because of the grain refinement, formation of dislocations, and dispersion strengthening. These positive significances of synchronous rolling provide a new direction for laser cladding technology.

36 MATERIALS SCIENCE↗

Effect of Cold Rolling and Heat Treatment on Microstructure and Mechanical Properties of Ti-4Al-1Mn Titanium Alloy

Mechanical behavior of Ti-4Al-1Mn titanium alloy has been studied in annealed, cold-rolled and heat-treated conditions. Room temperature tensile strength as well as % elongation has been found to be low with increasing amount of cold rolling. Lowering of strength in cold worked condition is attributed to premature failure. However, the same has been mitigated after heat treatment. Significant effect of cooling media (air and water) from heat treatment temperature on microstructure was not found except for the degree of fineness of α plates. Optimum properties (strength as well as ductility) were exhibited by samples subjected to 15% cold rolling and heat treatment below β transus temperature, which can be attributed to presence of recrystallized microstructure. In cold worked condition, the microstructure shows fine fragmented α plates/Widmanstätten morphology with high dislocation density along with a large amount of strain fields and twinning, which gets transformed to recrystallized equiaxed microstructure and with plate-like morphology after near β heat treatment. Prior cold work is found to have a significant effect on mechanical properties supported by evolution of microstructure. Twinning is found to be assisting in deformation as well as in recrystallization through the formation of deformation and annealing twins during cold working and heat treatment. Fracture analysis of the tested sample with prior cold work and heat-treated condition revealed quasi-ductile failure as compared to only ductile failure features seen for samples heat treated without prior cold work.

36 MATERIALS SCIENCE↗

Microstructure, Texture, and Mechanical Properties of Ni-W Alloy After Accumulative Roll Bonding

In this study, the microstructure, texture, and mechanical properties evolution of Ni-14W (wt.%) alloy processed up to four cycles of accumulative roll-bonding (ARB) were investigated using electron backscatter diffraction, microhardness measurements, and tensile tests. The initial equiaxed grains, with an average size of 10 μm, underwent a strong refinement after ARB processing. The elongated ultrafine grains were parallel to the rolling direction, with a grain thickness of 0.2 µm. The texture after ARB processing was characterized by the typical rolling components (Copper, S and Brass), which showed a tendency toward stabilization after four cycles. The microhardness increased substantially (+ 86%) and seemed to saturate after three cycles. The tensile tests demonstrated that Ni-14W samples subjected to ARB processing exhibited high strength (> 1200 MPa after three ARB cycles) and very poor ductility.

36 MATERIALS SCIENCE↗

Microstructure Evolution and Mechanical Property of Low-Alloy Steel Used for Armor Layer of Flexible Pipe During Thermomechanical Process and Hot Rolling Process

In this paper, the thermomechanical process and hot rolling process were carried out to study the microstructure evolution and mechanical property of low-alloy steel used for armor layer of flexible pipes by analyzing continuous cooling transformation curve, microstructure morphology, grain characteristics, and strength. The experimental results indicate that deformation process promotes phase transformation process of both ferrite and bainite and induces the formation of fine grain. The density of low-angle grain boundary rises with increasing cooling rate. The dislocation concentration in grain becomes larger with the extended cooling rate. The microstructure of hot-rolled specimen consists of polygonal ferrite and granular bainite, which is consistent with one of the deformed specimens with similar cooling rate in dilatometer. The microstructure evolution provides effective data fundament for hot rolling process.

36 MATERIALS SCIENCE↗

Origin of the {111}〈112〉 Cold Rolling Texture Development in a Soft Magnetic Fe-27%Co Alloy

Plastic deformation of Fe-27%Co alloy at room temperature was investigated. The present alloy, usually delivered with a low-texture component for the magnetic core in rotating machines, develops a rather high intensity of Goss texture after recrystallization, when a suitable manufacturing process is applied. Thanks to this texture and its magnetic properties, this material can replace the grain-oriented Fe-3%Si alloy in electric transformer application. The intensity of the recrystallization Goss component depends directly on the sharpness of the {111}〈112〉 orientation developed during cold rolling. Thus, the origin of this {111}〈112〉 deformation texture has been studied using visco-plastic self-consistent (VPSC) simulations. This model showed that only the {110}〈111〉 slip systems allow developing the {111}〈112〉 texture. The predominance of this slip system has been effectively identified from slip markings on the deformed sample by EBSD. More, this simulation has shown that a Goss texture at the hot-rolled state favors the {111}〈112〉 development during cold rolling, as observed experimentally.

36 MATERIALS SCIENCE↗

Effect of Anisotropy on Microstructures and Mechanical Properties of Rolled Ti/Al/Mg/Al/Ti Laminates

TA2/5052Al/AZ31/5052Al/TA2 five-ply laminates were fabricated by hot rolling, and the effect of anisotropy on their microstructures and mechanical properties was studied. After rolling, the Mg/Al and Al/Ti interfaces were both closely connected, but the interfacial shapes were totally different. For the Mg layer microstructures in the middle area, regardless of the direction, dynamic recrystallized (DRXed) grains appeared around the deformation bands. However, twins and a shear zone appeared in the RD sample; the twins decreased in the sample along the 45° angle, and no twins appeared in the TD sample. The Ti layer showed equiaxed grains in different directions, which were attributed to the ability of Ti alloy to anti-deform. The tensile testing results showed that the fracture of the Ti/Al/Mg/Al/Ti laminates can be divided into four stages. The laminate had an ultimate tensile strength of 434 MPa and excellent elongation along the rolling direction (RD), which were attributed to its DRXed grains and twins. In conclusion, the laminates had significant anisotropy due to the presence of Mg alloys.

36 MATERIALS SCIENCE↗

Effect of Electropulsing on Surface Mechanical Behavior and Microstructural Evolution of Inconel 718 during Ultrasonic Surface Rolling Process

In the current study, the surface mechanical behavior and microstructural evolution of Inconel 718 superalloy processed by the ultrasonic surface rolling process (USRP) and electropulsing-assisted ultrasonic surface rolling process (EP-USRP) were carefully analyzed. The experimental results suggested that after EP-USRP with a frequency of 400 Hz, significant enhancements in Vickers microhardness and nanoindentation hardness were achieved compared to those of USRP specimens, with increases of 13.6 and 9.9%, respectively. Moreover, the machined surface quality, wear resistance, and thermal stability were also improved after EP-USRP (400 Hz). These enhancements in mechanical behavior are closely related to the microstructural evolution induced by electropulsing. Under the coupling of thermal and athermal effects of high-energy electropulsing, the deformation limit of USRP is surpassed and a new balance is achieved between the electropulsing softening effect and the ultrasonic rolling hardening effect. Therefore, further grain refinement, improved plastic deformation ability in the strengthened layer, and the interaction effect between nano-sized precipitates and grain boundaries are probably the main reasons for these results.

36 MATERIALS SCIENCE↗

Influence of rolling reduction and annealing on recrystallization and grain structure in Ta-2.5W alloys

The microstructural evolution of wrought Tantalum - 2.5 wt% Tungsten (Ta-2.5W) alloys during thermomechanical processing is critical for optimizing their mechanical reliability in demanding applications such as aerospace, chemical processing, and nuclear technology. Despite the widespread use of Ta-W alloys, a comprehensive understanding of how rolling reduction, annealing temperature, and elemental inhomogeneity interact to determine recrystallization behavior and grain refinement remains incomplete. Here, in this study, we systematically investigate the effects of cold rolling and subsequent annealing on the microstructure of Ta-2.5W, with particular attention to grain orientation, stored energy, and elemental banding. Our results demonstrate that higher rolling reduction rates lower the onset and completion temperatures for recrystallization, resulting in finer and more homogeneous grain structures. Electron backscatter diffraction (EBSD) analysis reveals that grains with a 〈111〉 parallel to the plate normal possess higher stored energy and nucleate recrystallization more readily than grains with a 〈001〉 parallel to the plate normal. Elemental mapping shows that tungsten inhomogeneity leads to localized bands of accelerated recrystallization and hardness variation. These findings provide new insights into the mechanisms of microstructure refinement in Ta-2.5W alloys, offering guidance for tailoring processing routes to achieve superior performance in demanding engineering environments.

Annealing↗

Tensile properties of co-rolled Zr/U-10Mo fuel at ambient and elevated temperatures

The United States High Performance Research Reactor (USHPRR) initiative is currently interested in replacing high-enriched uranium fuel in research reactors with high-assay low-enriched uranium fuel. Here, this work aimed to assist in that mission by providing tensile and bend test data on bare U-Mo and tensile test data on co-rolled Zr/U-10Mo plates at differing thicknesses (0.285 mm, 0.300 mm, and 0.465 mm) and temperatures (293 K, 473 K, and 623 K). Yield strength and ultimate tensile strength values are reported along with an in-depth comparison of how temperature, rolling direction, thickness, and the presence of the Zr-interlayer affect mechanical properties. Results showed that yield strength and ultimate tensile strength in Zr/U-10Mo foils lower as temperature increases by approximately 300 MPa from 293 to 473 K, and another 100 MPa from 473 to 623 K. Additionally it was found that with increased temperature, there is less differentiation in fuel necking and delamination behavior, as well as a greater perceived elongation to fracture. The elastic modulus of co-rolled mini-plates does not follow the volumetric rule of mixtures in terms of averaged strength and is actually lower than the reported moduli of both Zr and U-10Mo.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Thermal etching of silver: Influence of rolling defects

Silver is well known to be thermally etched in an oxygen-rich atmosphere and has been extensively studied in the laboratory to understand thermal etching and to limit its effect when this material is used as a catalyst. Yet, in many industrial applications the surface of rolled silver sheets is used without particular surface preparation. Here, it is shown by combining FIB-tomography, FIB-SIMS and analytical SEM that the kinetics of thermal etch pitting are significantly faster on rolled Ag surfaces than on polished surfaces. This occurs due to range of interacting phenomena including (i) the reaction of subsurface carbon-contamination with dissolved oxygen to form pores that grow to intersect the surface, (ii) surface reconstruction around corrosion pits and surface scratches, and (iii) sublimation at low pressure and high temperature. A method to identify subsurface pores is developed to show that the pores have (111) and (100) internal facets and may be filled with a gas coming from the chemical reaction of oxygen and carbon contamination. - Highlights: Thermal etching of industrial silver sheets vs. polished silver sheets Effect of annealing atmosphere on the thermal etching of silver: surface and subsurface characterization Link between etch pitting and defects induced by rolling. FIB-tomography coupled with EBSD for determining crystal planes of the facets of subsurface pores. FIB-SIMS characterization to probe the gas confined inside subsurface pores.

36 MATERIALS SCIENCE↗

Interface-correlated bonding properties for a roll-bonded Ti/Al 2-ply sheet

Highlights: • The feasible post roll-bonding annealing condition of Ti/Al clad was deduced. • The optimum thickness of the TiAl{sub 3} IMC diffusive layer is about 200 nm. • A ‘zipper-like’ failure mode at the interface yields the maximum bonding strength. - Abstract: We investigated the influence of annealing conditions on the interface-correlated microstructural evolution and subsequent bonding properties of a warm roll-bonded Ti/Al clad sheet. A TiAl{sub 3} intermetallic compound layer with a thickness of 160 nm was initially generated at the joint interface between the Ti and Al alloys by warm rolling. When the annealing time and temperature were increased to a maximum of 6 h and 650 °C, respectively, the thickness of the TiAl{sub 3} layer increased to 320 nm. The feasible annealing conditions for the optimum bonding strength were within 550 °C-6 h and 600 °C-3 h. An improvement in the bonding strength between Ti and Al is strongly correlated with the generation of considerable metallurgical bonding. This is manifested in the zipper-like failure mode that occurs at the TiAl{sub 3} joint interface for a layer thickness of less than 300 nm.

36 MATERIALS SCIENCE↗

Continuous microstructure evolution of ball rolled TWIP Ti15Mo alloy and its effect on phase precipitation behavior

Highlights: • Gradient microstructure was induced by ball rolling method in a Ti15Mo alloy. • Twin density increased and then decreased as increasing distance from surface. • Ultrafine (α + β) duplex structure was formed in the heavily deformed region. • α-phase in plate was precipitated in twined region in slightly deformed region. • Strengthening by formation of sub/nano-grains was notable than that by twins. - Abstract: A β-type Ti15Mo alloy with {332}<113> twinning-induced plasticity (TWIP) effect was utilized to investigate the continuous microstructure evolution of β-matrix by ball rolling method. Precipitation behavior of α-phase and strengthening mechanism were examined in regions with different strain. Amounts of intersected twins were present in the slightly deformed region of β-matrix, and their area fraction decreased with an increase of distance from rolled surface. The β-matrix close to surface was heavily deformed to result in the formation of abundant subgrains and nanograins, which was caused by cooperative occurrence of twinning refinement, intragranular dislocation activities and subgrain rotation. Mechanical twins provided the preferential nucleation sites for plate-like α-phase with strong variant selection. Equiaxed α-phase preferentially nucleated at the boundaries of subgrains and nanograins with weak variant selection to form the ultrafine (α + β) duplex structure. Due to the formation of subgrains and nanograins as well as the strain hardening, strengthening became more significant than that by twinning refinement solely. Similarly, the ultrafine (α + β) duplex structure exhibited a better strengthening effect than that by precipitation of plate-like α-phase. The diversities of deformation microstructure combined with different precipitation behaviors of α-phase are desirable for controlling the mechanical properties of β-type TWIP titanium alloys.

36 MATERIALS SCIENCE↗