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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Failure Strain and Related Triaxiality of Aluminum 6061-T6, A36 Carbon Steel, 304 Stainless Steel, and Nitronic 60 Metals, Part I: Experimental Investigation

The objective of this study is to develop failure-limit material models for Aluminum 6061-T6, A36 Carbon Steel, 304 Stainless Steel, and Nitronic 60 metals, based on parameters of plastic equivalent strain (failure strain) and stress triaxiality. The research is conducted in two parts. This paper presents Part One of the study. In Part One, custom-designed test specimens undergo controlled uniaxial tension and compression testing at ambient temperature. These tests are performed at quasi-static speeds using Universal Testing Machines (UTMs) in accordance with ASTM E8 and ASTM E9 standards. Experimental data, specifically engineering stress–strain and force–displacement curves, are recorded from the onset of loading until specimen fracture, or in the case of compression tests, until the capacity of the testing machine is reached. In Part Two, the emphasis shifts to the calibration of Finite Element Analysis (FEA) models of the custom-designed test specimens. Plastic equivalent strain and the corresponding stress triaxiality values at failure are extracted from each test specimen for the given metal. These values are then systematically plotted onto a single graph to construct the failure-limit curve, which delineates the boundary conditions for material failure. This approach will facilitate the development of a comprehensive material property definition that correlates plastic equivalent strain with stress triaxiality at failure for Aluminum 6061-T6, A36 Carbon Steel, 304 Stainless Steel, and Nitronic 60 metals.

Harwell, Ron↗
DOE OSTI2023

Interfacial microstructure and mechanical properties of rotary inertia friction welded dissimilar 422 martensitic stainless steel to 4140 low alloy steel joints

In this work, dissimilar rotary inertia friction welds between 422 martensitic stainless steel and 4140 martensitic low-alloy steel were made to fabricate prototype heavy-duty diesel engine pistons. The influence of the inertia friction welding process and post weld heat treatment (PWHT) temperature on the interfacial microstructure evolutions and corresponding effects on mechanical properties of the 422/4140 welds were evaluated in detail. Carbon diffused from the 4140 side to the 422 side during PWHT at 650 °C for 1.5 h, causing the formation of a hard carbide-rich layer on the 422 side, and a softer but discontinuous C-depleted layer the 4140 side. PWHT at 700 °C for 1.5 h greatly accelerated C diffusion across the interface relative to 650 °C, resulting in a thicker hard carbide-rich layer and a relatively thick and continuous layer of coarse C-depleted grains (ferrite) on the 4140 side. In addition, the PWHT temperature greatly influenced the tensile properties and fracture behavior of the welds, with the 650 °C PWHT-ed samples failing predominately in a ductile manner in the 4140 heat affected zone during tensile testing. Conversely, the 700 °C PWHT specimens exhibited a strength reduction compared with the 650 °C PWHT specimens because of additional coarsening of the interfacial ferrite layer and softening of the base materials during PWHT, with brittle fracture between the hard and soft layers the predominate failure mechanism. Based on the findings, a reduced PWHT temperature and/or time, minimizing the hardness differential of the base metals, and pre-heating the 422 steel prior to welding are the potential pathways to achieve a more optimal balance between desirable tempering and stress relief of the weld microstructure and undesirable C migration across the weld interface, and to reduce the strength mismatch across the weld.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Evaluation of thermal processing and properties of 422 martensitic stainless steel for replacement of 4140 steel in diesel engine pistons

The thermal and mechanical properties of martensitic stainless steel 422 were evaluated for suitability as a drop-in replacement for 4140 steel in next generation heavy-duty diesel engine (HDDE) pistons. The time and temperature of the austenitization and tempering steps were studied to achieve optimum materials performance in piston applications, including the balance of thermal and mechanical properties and resistance to long-term thermal aging. Reducing the tempering temperature from 700 to 600 °C caused a substantial increase in elevated temperature strength from 25 to 600 °C, but had no significant influence on thermal conductivity, suggesting that thermal conductivity in 422 is dominated largely by composition and distribution of alloying elements and mostly independent of the sub-grain structure size and precipitate size. Compared to the current HDDE piston alloy 4140, 422 exhibits substantially higher elevated temperature strength and lower thermal conductivity, the latter which will cause 422 to operate at higher temperatures in pistons, possibly requiring a piston redesign to take advantage of the improved high temperature strength of 422. Piston material selection and alloy design strategies with potential to mitigate some of the shortcomings of martensitic stainless steels, such as 422, as drop-in replacements are discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Effect of nickel on the kinematic stability of retained austenite in carburized bearing steels – In-situ neutron diffraction and crystal plasticity modeling of uniaxial tension tests in AISI 8620, 4320 and 3310 steels

The presence of kinematically metastable retained austenite in the microstructure of bearing components can significantly affect the macro and micro-mechanical material response. In the present work, the influence of Ni on the stability of the retained austenite within three different grades of high carbon bearing steel using in-situ neutron diffraction is investigated. For the first time, the results show that presence of Ni increases the stability of the austenite in the elastic regime whereas the transformation rate remains unaffected. Crystal plasticity finite element (CPFE) modeling was used to study the deformation in these three steels and shows that the predominant factor causing the difference in mechanical behavior of these steels is the austenite stability. Finally, the elastic and plastic response of the matrix martensite was found to be identical among all specimens while the austenite demonstrates similar elastic behavior but remarkably different stabilities under monotonic loading.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Friction Stir Dovetailing of AA7099 to Steel with AA6061 Interlayer for Reduced Zn Embrittlement at Dissimilar Interface

Joining of high strength Al alloy (AA7099) to steel (rolled homogeneous armor) with and without AA6061 interlayer was achieved using a friction stir dovetailing (FSD) method. Detailed investigations were conducted to establish correlations between mechanical performance and microstructural evolution of FSD joints. Lap shear tensile testing revealed that incorporation of the AA6061 interlayer combined with tailored processing methodology significantly improved both mechanical interlocking and load transmission across the dovetail interface. Following incorporation of the interlayer, the maximum load carrying capacity and peak extension (of the AA7099/AA6061/steel joint) are 60% and 210% higher, respectively, than results obtained from an AA7099/steel joint without an interlayer. Without an AA6061 interlayer, formation of zinc rich intermetallic compounds led to brittle interfacial failure of the AA7099-steel FSD joint. Incorporation of novel tool and joint configuration eliminated asymmetric joint performance as a function of loading direction, which is generally observed in friction stir lap welding. The efficacy of the use of an AA6061 interlayer in joining AA7099 to steel was demonstrated through mechanical testing as well as high resolution analytical electron microscopy characterization.

Dissimilar metal joining, Friction stir dovetailin↗
DOE OSTI2022

Towards directed energy deposition of metals using polymer-based supports: porosity of 316L stainless steel deposited on carbon-fiber-reinforced ABS

Directed energy deposition (DED) is increasingly valuable to many industries because of its high deposition rates relative to other metal additive manufacturing processes, but the design space of DED is limited. For instance, steep overhangs are difficult or impossible to manufacture. Polymer-based support structures could help address this challenge. The viability of DED on polymer composite substrates has begun to be explored, specifically with 316L stainless steel on carbon-fiber-reinforced ABS substrates. Monolithic metal components can be deposited on the polymer, but it was found that gas release during polymer degradation causes porosity due to gas entrapment in the metal. An interlayer cooling time was introduced to reduce polymer degradation and decrease the porosity due to gas entrapment, but this led to porosity from lack of fusion. The results of this work provide insight into process parameter selection and scan strategy development to enable the use of polymer support structures in blown-powder DED.

Kurfess, Rebecca↗
NASA NTRS1973

Gas-phase hydrogen permeation through alpha iron, 4130 steel, and 304 stainless steel from less than 100 C to near 600 C

Gas phase hydrogen permeation studies were conducted on hollow, cylindrical membranes of triply zone-refined alpha iron, AISI 304 austenitic stainless steel, and AISI-SAE 4130 steel in both the normalized (ferrite and carbide) and quenched and tempered (martensite) conditions. Membrane temperature was varied from less than 100 C to near 600 C and hydrogen pressure was varied. For one membrane material, normalized 4130 steel, gas phase hydrogen transport under both steady state and nonsteady state conditions was demonstrated to be controlled by lattice diffusion. Additionally, Sievert's law was shown to be applicable. For all membrane materials, expressions for the coefficients for hydrogen permeation were determined by analysis of steady state transport; the coefficients for diffusion were determined by the lag time technique applied to nonsteady state transport; and through a knowledge of the Sievert's constants, the subsurface equilibrium lattice hydrogen concentrations were determined.

Nelson, H. G.↗
NASA NTRS1978

Influence of fretting on flexural fatigue of 304 stainless steel and mild steel

Fretting fatigue experiments conducted on 304 stainless steel using a flexural fatigue test arrangement with bolted on fretting pads demonstrated that fatigue life is reduced by at least a factor of 10 in the 265 to 334 MPa (38,500 - to 48,500 psi) nominal flexural fatigue stress range. In addition, experiments in which the fretting pads were removed after selected numbers of cycles, followed by continued flexural fatigue without fretting show that continued fretting beyond 50,000 cycles does not significantly further reduce fatigue life of 304 stainless steel at 317 MPa (46,000 psi). Microscopic examination of the fretted contact areas revealed fracture initiation sites as well as numerous cracks that did not propagate to failure. Flexural fretting fatigue experiments performed on mild steel showed an insensitivity of fatigue life to the incidence of fretting under flexural stress conditions of from 162 to 217 MPa (23,500 to 31,500 psi).

Bill, R. C.↗
NASA NTRS1979

Study of austenitic stainless steel welded with low alloy steel filler metal

The tensile and impact strength properties of 316L stainless steel plate welded with low alloy steel filler metal were determined. Tests were conducted at room temperature and -100 F on standard test specimens machined from as-welded panels of various chemical compositions. No significant differences were found as the result of variations in percentage chemical composition on the impact and tensile test results. The weldments containing lower chromium and nickel as the result of dilution of parent metal from the use of the low alloy steel filler metal corroded more severely in a marine environment. The use of a protective finish, i.e., a nitrile-based paint containing aluminum powder, prevented the corrosive attack.

Burns, F. A.↗
DOE OSTI2023

SA508 low alloy steel to 316L stainless steel dissimilar metal joint made by powder metallurgy hot isostatic pressing

Joining ferritic SA508 low alloy steel (LAS) and austenitic 316 L stainless steel (SS) via powder metallurgy hot isostatic pressing (PM-HIP) was evaluated as an alternative method to welding. This study investigated the mechanical and microstructural evolutions of the bimetallic interface under different joint designs and heat treatments. Here, the direct joining of dissimilar metal alloys by PM-HIP method resulted in two designs: 1) powder SA508 to solid bar 316 L (P508–B316L) and 2) powder 316 L solid bar SA508 (P316L-B508). In both cases, P508–B316L and P316L-demonstrated satisfactory tensile strength, however, high hardness and severe depreciation in toughness were located on the bimetallic interface. The mechanisms responsible for the detrimental mechanical properties were verified. Large oxides were observed in P508–B316L due to the prior powder boundary (PPB) oxides present in SA508 powder. The intense sensitization occurred from the formation of M 23 C 6 carbides, consequently from the slow cooling after PM-HIP in P316L-B508. Post-HIP heat treatments were explored to reduce the distance of carbide formation; however, the heat treatment could not eliminate the carbides. The experimental results were compared to the diffusion couple simulation as a function of carbide formation with distance. The analysis also showed the high hardness at the bimetallic interface was primarily contributed by solid solution strengthening. In conclusion, the direct joining of P316L-B508 and P508–B316L via PM-HIP was deemed to be unfeasible, and a transitional material is necessary to impede the diffusion of carbon.

316L stainless Steel↗
DOE OSTI2020

Galvanic Corrosion of Carbon Steel and Stainless Steel Couples: Effects of γ-Radiation and Solution Environment - 20348

Galvanic corrosion between carbon steel (CS) and stainless steel (SS) in different aqueous environments was investigated using a combination of electrochemical measurements and surface characterizations. In a basic environment (pH 10.6), the galvanic effect is negligible due to the high corrosion resistance of both alloys. In an acidic to near neutral environment (pH 6.0), the galvanic effect is more significant. Coupling to SS, increasing temperature, and irradiation at this pH have a synergistic effect on the corrosion progression of CS, and their effects vary with time. Initially, the oxidation rate of CS increases after galvanic coupling to SS. Increasing temperature or applying γ-radiation accelerates this oxidation process. However, at a longer time when the saturation limits of metal cations are reached, they also lead to the formation and growth of oxides on CS at a much faster rate, resulting in the suppression of the subsequent Fe dissolution. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Tritium embrittlement of austenitic stainless-steel tubing at low helium contents

Austenitic stainless steels are the standard materials for containment of hydrogen and tritium because of their resistance to mechanical property degradation in those environments. The mechanical performance of the primary containment material is critical for tritium handling, processing, and storage, thus comprehensive understanding of the processes of tritium embrittlement is an enabling capability for fusion energy. This work describes the investigation of the effects of low levels of tritium-decay-helium ingrowth on 304 L tubes. Long-term aging with tritium leads to high helium contents in austenitic stainless steels and can reduce fracture toughness by 95 %, but the details of behavior at low helium contents are not as well characterized. Here, we present results from tensile testing of tritium pre-charged 304 L tube specimens with a variety of starting microstructures that all contain a low level of helium. The results of the tritium exposed-and-aged materials are compared to previously reported results on similar specimens tested in an unexposed condition as well as the hydrogen precharged condition. Tritium precharging and aging for a short duration resulted in increased yield strengths, ultimate tensile strengths and slightly increased elongation to failure, comparable to higher concentrations of hydrogen precharging.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Microstructure characteristics of LPBF&HIP fabricated graded composite transition joint between ferritic steel and austenitic stainless steel

Graded composite transition joints (GCTJs) offer a promising alternative to conventional dissimilar metal welds (DMWs) by enabling smooth compositional and microstructural transitions. However, GCTJs fabricated solely through additive manufacturing (AM) face challenges such as heat accumulation, complex parameter control, and elemental segregation. In this study, we propose a novel approach that relies on AM to design a spatially graded structure in one alloy and then employs hot isostatic pressing (HIP) as a diffusion bonding method to join it with a second alloy. Here, this method combines the flexibility of AM with the powder net-shaping advantage of HIP. Specifically, a series of closely packed austenitic stainless steel 304 conical structures were printed using laser powder bed fusion (LPBF) and then combined with ferritic steel P91 powder via HIP. By using electron backscatter diffraction (EBSD), electron probe microanalysis (EPMA), and transmission electron microscopy (TEM) techniques, the microstructure characteristics of the GCTJ of 304&P91, especially the interdiffusion zone (IDZ), have been systematically investigated. The microstructure at the interface transitions from austenite-ferrite (A+F) to austenite-martensite-ferrite (A+M+F), and finally to martensite-ferrite (M+F) due to diffusion. Additionally, the diffusion width between 304 and P91 increases with the volume fraction of P91. This unique design also ensures a gradual transition in both hardness and thermal expansion coefficient from 304 to P91, thereby enabling a smooth gradient in functional properties. Overall, this study proposes a novel approach for fabricating GCTJs and contributes to advancing design concepts in the field of dissimilar metal joining.

Additively manufacturing (AM)↗
DOE OSTI2020

Microstructure, hardness and cavitation erosion resistance of different cold spray coatings on stainless steel 316 for hydropower applications

There is an urgent need for repair of hydropower components that have undergone damage due to cavitation. Conventional repair methods involve melting of materials and can deteriorate material properties and cause distortion. This study investigated the relevant properties of different materials using solid phase processing—cold spray technology. Stainless steel (SS) 316, Inconel 625 and CrC-NiCr materials were cold spray deposited onto base metal SS 316, respectively. Cold spray achieved dense uniform deposits with low level porosity, and intimate contact between the deposit and the base metal was observed. Severe plastic deformation imparted during the cold spray process resulted in significant grain size refinement, nanostructured regions were observed in the deposits across the interfacial area. Cold sprayed deposits exhibited elevated hardness in contrast to that of the base metal SS 316. The cavitation erosion resistance of the deposits was evaluated with a cavitation erosion jet adhering to ASTM G134. Both SS 316 and Inconel 625 achieved better cavitation erosion resistance when compared to that of the SS 316 base metal, with the former exhibiting close to a 4 times improvement.

Jiang, Xiujuan↗