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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 OSTI2020

Numerical Simulation and Experimental Validation of Joint Performance in Aluminum-Steel Lap Welds Formed by Friction Stir Dovetailing

Friction stir dovetailing (FSD) is a new dissimilar material joining process that simultaneously forms a mechanical interlock and metallurgical bond at the dissimilar material interface. This work presents development of a modeling and simulation approach to predict mechanical performance of FSD thick section aluminum to steel joints. A finite element analysis (FEA) was carried out in order to predict the load-carrying capacity and failure location for aluminum thicknesses between 12.7 mm and 50.8 mm with different numbers of dovetails. The numerical results and corresponding experimental investigation are in agreement and suggest that the developed methods can be used effectively for design and analysis of FSD joints using standard FEA tools.

Friction stir dovetailing, Friction stir welding, ↗
NASA NTRS1966

Momentum Transfer and Cratering Phenomena Associated With the Impact of Aluminum Spheres Into Thick Aluminum Targets at Velocities to 24,000 Feet Per Second

Spheres of 2017-T4 aluminum with diameters of, 1/16, 1/8, and ½ inch were launched into semi-infinite targets of 2024-T4 and 1100-0 aluminum. The momentum transfer during impact was measured by means of a simple ballistic pendulum to which the target was attached. The ratio of target momentum to projectile momentum increased with increasing projectile velocity and with projectile diameter. Mass loss due to cratering, penetration, and crater diameter were also obtained for these experiments. It was noted that the variation of these parameters was also a function of the projectile diameter. No conclusive evidence was uncovered to explain this apparent scale effect. However, close examination of the various craters suggests that the cratering process is, in fact, different for the different size projectiles. The cause for this difference has yet to be resolved.

MOMENTUM TRANSFER↗
DOE OSTI2021

Thermodynamic stabilization of nanocrystalline aluminum

Nanocrystalline metals are generally unstable due to a large volume fraction of high-energy grain boundaries associated with a small grain size. Preferential dopant segregation to the high-energy grain boundaries is observed to enhance the stability of the material’s microstructure by minimizing its energy. Nanocrystalline aluminum-dopant systems were evaluated for thermodynamic stability against grain growth and phase precipitation via the mechanism of grain boundary segregation according to a modified regular nanocrystalline solution model. Fifty-one potential dopant elements have been evaluated for their efficacy in stabilizing nanostructures with three potential candidates, magnesium, lanthanum, and silicon, identified possessing the characteristics to promote grain boundary segregation and a state of thermodynamic stability in aluminum’s nanocrystalline regime. Here, the minimum dopant content required to achieve nanocrystalline microstructure stability is identified for each of the three candidate elements. Beyond this minimum content, further addition of the dopant elements decreased the final microstructure’s stability with no effects on the existence of a stable nanocrystalline state.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Influence of soluble oligomeric aluminum on precipitation in the Al-KOH-H2O system

The role of oligomeric aluminate (Al(OH)4-) species in the precipitation of aluminum phases such as gibbsite (a-Al(OH)3) from aqueous hydroxide solutions remains unclear and difficult to probe directly, despite its importance to developing accurate predictions of Al solubility in highly alkaline systems. Precipitation in this system entails a transition from predominantly tetrahedrally coordinated Al species in solution to octahedrally coordinated Al in gibbsite. Here we report a quantitative study of dissolved Al in the Al-KOH-H2O system using a combination of molecular spectroscopies. We established a relationship between changes in 27Al NMR chemical shifts and the relative intensity of Raman vibrational bands, indicative of variations in the ensemble speciation of Al in solution, and the formation of unique contact ion pair interactions with the aluminate dimer, Al2O(OH)62 . A strong correlation between the extent of Al oligomerization and the amount of solvated Al was demonstrated by systematically varying the KOH:Al molar ratio. The concentration of dissolved oligomeric Al in solution also directly impacted the particle size and morphology of gibbsite; high concentrations of dimeric Al2O(OH)62-, yielded smaller and more numerous anhedral to subhedral gibbsite particles, while low concentrations yielded fewer and larger euhedral gibbsite platelets. The collective observations suggest a key role of the Al2O(OH)62- dimer in promoting gibbsite precipitation from solution, where the potassium ion-paired dimer possibly catalyzes a more rapid transformation of Al coordination from tetrahedral in solution to octahedral in gibbsite.

Dembowski, Mateusz↗
DOE OSTI2024

Drying and Analysis of Aluminum (Oxy)hydroxide Films for Dry Storage of Aluminum-Clad Spent Nuclear Fuels

In aluminum-clad spent nuclear fuels, an (oxy)hydroxide layer on the surface of the cladding hosts chemisorbed water formed during reactor and post-discharge exposure to water. Any residual water is susceptible to generating hydrogen via radiolysis, which can be a risk associated with dry fuel storage. Engineering-scale forced helium dehydration (FHD) and vacuum drying tests were conducted on mock-up fuel assemblies that included corroded aluminum surrogate plates to assess the removal of bulk and chemisorbed water. Thermogravimetric analysis was performed on samples of the surrogate plates, both undried control samples used to determine onset temperatures associated with a phase change occurring in the oxide layer and samples from drying tests used to determine the effectiveness of each drying method. Both vacuum drying and FHD processes were capable of removing bulk water. However, FHD was determined to provide additional drying capabilities, including partial removal of chemisorbed water from bayerite due to the higher temperatures during drying. In conclusion, the temperature threshold for partial dehydroxylation of the oxide layer was determined to be around 220°C, meaning any drying methods attempting to remove chemisorbed water must exceed 220°C.

chemisorbed water↗
DOE OSTI2021

Characterization of mechanical deformation in aluminum by optical second harmonic generation

Second harmonic generation (SHG), a laser-based surface technique, was used to characterize near-surface defect evolution associated with mechanical deformation in 2024-T3 aluminum due to tensile loads. Electron backscatter diffraction (EBSD) measurements were also performed to determine the geometrically necessary dislocation density before and after tensile deformation. Comparison of the EBSD and SHG results found that dislocation density and SHG signal are inversely proportional; tensile deformation in the plastic regime led to an increase in dislocation density and a decrease in SHG response. A similar trend was seen in the SHG results on as-received (unpolished) Al samples; SHG response decreases with extent of plastic deformation. Furthermore, this study suggests that SHG has potential as a nondestructive evaluation technique.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Visual Examination of Aluminum Containers for Extended Wet Storage of Non-Aluminum-Clad Spent Nuclear Fuel (FY 2021)

The goal of the Augmented Monitoring and Condition Assessment Program (AMCAP) program is to provide a condition assessment of the storage containers for non-aluminum-clad spent nuclear fuel (NASNF) in L Basin and demonstrate continued safe storage of all NASNF pending retrieval for ultimate disposition. The storage configuration of NASNF is vulnerable to inside-out corrosion attack. The approach being used in AMCAP is to develop and deploy examination methods for remote, in-situ inspection of the bundle storage in VTS and for OSC storage in the OSC racks. A method for Visual Examination (VE) using video-recording cameras was readied as part of the full-scale mockup development, and was deployed in L Basin for the initial condition assessment work. This report describes the development and the deployment of the VE for inspection of selected bundles in L Basin. The first deployment of the VE system was for visually examining five spent fuel bundles. Bundles were chosen based on their vulnerability in terms of inner fuel contents, history, storage duration, storage configuration, and possibility of inside out corrosion due to galvanic coupling of fuel cladding with the aluminum bundle wall.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1990

Elevated temperature crack growth in aluminum alloys: Tensile deformation of 2618 and FVS0812 aluminum alloys

Understanding the damage tolerance of aluminum alloys at elevated temperatures is essential for safe applications of advanced materials. The objective of this project is to investigate the time dependent subcritical cracking behavior of powder metallurgy FVS0812 and ingot metallurgy 2618 aluminum alloys at elevated temperatures. The fracture mechanics approach was applied. Sidegrooved compact tension specimens were tested at 175, 250, and 316 C under constant load. Subcritical crack growth occurred in each alloy at applied stress intensity levels (K) of between about 14 and 25 MPa/m, well below K (sub IC). Measured load, crack opening displacement and displacement rate, and crack length and growth rate (da/dt) were analyzed with several continuum fracture parameters including, the C-integral, C (sub t), and K. Elevated temperature growth rate data suggest that K is a controlling parameter during time dependent cracking. For FVS0812, da/dt is highest at 175 C when rates are expressed as a function of K. While crack growth rate is not controlled by C (sub t) at 175 C, da/dt appears to better correlate with C (sub t) at higher temperatures. Creep brittle cracking at intermediate temperatures, and perhaps related to strain aging, is augmented by time dependent transient creep plasticity at higher temperatures. The C (sub t) analysis is, however, complicated by the necessity to measure small differences in the elastic crack growth and creep contributions to the crack opening displacement rate. A microstructural study indicates that 2618 and FVS0812 are likely to be creep brittle materials, consistent with the results obtained from the fracture mechanics study. Time dependent crack growth of 2618 at 175 C is characterized by mixed transgranular and intergranular fracture. Delamination along the ribbon powder particle boundaries occurs in FVS0812 at all temperatures. The fracture mode of FVS0812 changes with temperature. At 175 C, it is characterized as dimpled rupture, and at 316 C as mixed matrix superplastic rupture and matrix-dipersoid debonding.

Leng, Yang↗
NASA NTRS2003

Effects of Forged Stock and Pure Aluminum Coating on Cryogenic Performance of Heat Treated Aluminum Mirrors

We present the results of an on-going test program designed to empirically determine the effects of different stress relief procedures for aluminum mirrors. Earlier test results identified a preferred heat treatment for flat and spherical mirrors diamond turned from blanks cut out of Al 6061-T651 plate stock. Further tests have been performed on mirrors from forged stock and one set from plate stock coated with Alumiplate(trademark) aluminum coating to measure the effect of these variables on cryogenic performance. The mirrors are tested for figure error and radius of curvature at room temperature and at 80 K for three thermal cycles. We correlate the results of our optical testing with heat treatment and metallographic data.

Toland, Ronald W.↗
DOE OSTI2020

Aluminum trihalide-neutral ligand ionic liquids and their use in aluminum deposition

An ionic liquid composition comprising a complex of a trihalo aluminum (III) species with at least one organic uncharged ligand comprising a ring structure having at least three ring carbon atoms and at least one ring heteroatom selected from nitrogen and sulfur, wherein the complex is a liquid at a temperature of 100° C. or less. Methods of electroplating aluminum onto a metallic substrate using the above-described ionic liquid composition are also described.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Development of a Castable High Strength Secondary Aluminum Alloy from Recycled Wrought Aluminum Scrap

A new process for recycling scrap AA7075 aerospace alloys directly into a high strength castable secondary alloy is demonstrated. The process involves enhancing the castability of the utilized primary wrought aluminum scrap feedstock by scrap alloy chemistry optimization and zirconium additions in order to mitigate the inherent hot tearing tendency of 7075 alloys. By utilizing the new process, the hot tearing index of scrap AA7075 was reduced from 26 to 4. Defect-free castings were obtained in pilot-scale castings trials. The developed secondary 7075 alloy also satisfied preset target mechanical properties with strength levels exceeding 250 MPa and elongation levels higher than 3%. The validity of the new approach and its readiness for transition to commercial practice was demonstrated by casting cylinder heads directly from the modified 7075 scrap.

36 MATERIALS SCIENCE↗