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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 361 records · Page 20
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

In-situ observation of oxygen mobility and abnormal lattice expansion in ceria during flash sintering

Flash sintering has been shown to be an effective method of sintering for many types of ceramics. However, the characteristics of flash sintering for each type of ceramic varies. When ionically conducting ceramics are sintered under a DC electric field, a strong dependence of densification with respect to position is observed. Microstructural analysis of the effect of electric field on oxygen ion conductors shows non-stoichiometry (oxygen deficiency) at the cathode which continues to build up over time under flash. In oxygen ion conductors, dominant charge carriers during flash are oxygen ions and the final density of the specimen is related to the availability of oxygen. This effect is no longer evident when using an AC power supply. In conclusion, use of AC instead of DC electric field is preferable for flash sintering of ionically conducting ceramics.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Silver diamine fluoride differentially affects dentin and hypomineralized enamel permeabilities

OBJECTIVES: To investigate the physicochemical effect of silver diamine fluoride (SDF) by correlating permeability with mineral density and elemental composition of hypomineralized enamel and carious dentin. METHODS: Enamel and dentin from human carious primary teeth with and without SDF treatment in-vivo, and hypomineralized enamel from permanent molars with and without SDF treatment in-vitro were scanned using micro X-ray computed tomography. Spatial maps of biometals (calcium, zinc), phosphorus, and silver were generated using X-ray fluorescence microprobe. Permeabilities were computed using Porous Microstructure Analysis software. RESULTS: The intrinsic permeability of SDF-treated carious dentin was 14.3 % lower than untreated sound dentin (6.39e-15 ± 3.01e-15 m² vs 7.46e-15 ± 1.82e-15 m²; P < 0.0001), while untreated carious dentin was 98.4 % higher (1.48e-14 ± 7.11e-15 m²; P < 0.0001). SDF-treated and untreated transparent dentin showed similar reduced permeabilities (75.6 % and 78.4 % lower than untreated sound dentin, respectively; P = 0.93). Severely hypomineralized enamel showed permeability reaching 108.1 % of adjacent sound dentin (5.71e-15 ± 2.04e-15 m² vs 5.28e-15 ± 1.30e-15 m²; P = 0.1409) and was significantly higher than mildly hypomineralized enamel (1.39e-15 ± 1.04e-15 m²; P < 0.0001). SDF treatment did not significantly impact the permeability of severely hypomineralized enamel (12.4 % reduction; P = 0.07). Principal component regression identified Zn level as a significant effector of tissue permeabilities in carious primary teeth (P < 0.0001). SIGNIFICANCE: This study introduces a computational method to measure dental tissue permeability, and demonstrates that SDF significantly reduces permeability in carious dentin but not intact hypomineralized enamel. The study reveals biometal Zn localization can alter dentin and enamel permeabilities, providing new insights into pathobiological mechanisms underlying caries and hypomineralization.

Chou, Conrad↗
DOE OSTI2022

Electrochemical noise studies on localized corrosion of Ni and Ni-20Cr in molten ZnCl 2

The electrochemical noise (ECN) technique was employed to study corrosion of two model systems, i.e. pure Ni and a binary Ni-20 wt%Cr (Ni20Cr) alloy in molten ZnCl 2 at 623 K. Here we measured ECN transients in current and open-circuit potential from two nominally identical Ni-Ni and Ni20Cr-Ni20Cr electrodes and one galvanic Ni-Ni20Cr electrode pair. The behavior of ECN is quite distinct among the three-electrode systems, and it is correlated with the various microscopic observations of micro- and nano-scale morphological features. Based on the ECN study coupled with the microstructural analysis, the origins of ECN in the molten salt environment as well as the mechanisms of localized corrosion in the three systems are discussed.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Strong effect of liquid Fe–S on elastic wave velocity of olivine aggregate: Implication for the low velocity anomaly at the base of the lunar mantle

The origin of the seismic low velocity zone (LVZ) observed at the base of the lunar mantle is important for understanding the nature of the lunar mantle. Liquid Fe–S is considered as a possible candidate of the cause of the LVZ. However, effect of liquid Fe–S on elastic wave velocity of mantle rock has been considered to be minor, according to theoretical estimation based on the high dihedral angle of liquid Fe–S in olivine aggregate observed in previous microstructural analysis of polished sample cross sections. Here, in this work, we carry out direct measurements of elastic wave velocities of liquid Fe–S-bearing olivine aggregate and report strong reduction of the elastic wave velocities in the presence of liquid Fe–S. The effects of liquid Fe–S in olivine aggregates are much more pronounced than the theoretical estimation. Three-dimensional X-ray microtomography analysis reveals that the geometry of liquid Fe–S strongly depends on the size, with larger liquid Fe–S blobs having low aspect ratios, which may predominantly affect elastic wave velocity. Since smaller spherical Fe–S blobs are much more abundant than the larger elongated blobs, conventional dihedral angle analyses based on scanning electron microscope images tend to statistically over-sample smaller blobs and under-sample larger blobs. Our results suggest that the LVZ at the base of the lunar mantle can be explained by the presence of 4.3–5.0 vol.% liquid Fe–S. The LVZ may be a hidden reservoir of highly siderophile elements (HSEs), which may explain the low abundance of HSEs in the lunar mantle compared to the Earth.

58 GEOSCIENCES↗
DOE OSTI2021

Technological aspects in blanket design: Effects of micro-alloying and thermo-mechanical treatments of EUROFER97 type steels after neutron irradiation

Presently available data on neutron irradiation damage raise doubts on the feasibility of using EUROFER97 steel for a water-cooled starter blanket in a DEMO reactor, since the ductile-to-brittle transition temperature (DBTT) increases significantly for irradiation temperatures below 350°C. The additional DBTT shift caused by H and He transmutation can only be estimated based on very few results with isotopically tailored EUROFER97 steel. Conservative calculations show that the DBTT of EUROFER97 steel could exceed the operating temperature in water-cooled starter blankets within a relatively short time period. This paper presents results from a EUROfusion funded irradiation campaign that was performed in the High Flux Isotope Reactor at Oak Ridge National Laboratory. The paper compares ten newly developed reduced activation ferritic-martensitic (RAFM) steels irradiated to a nominal dose of 2.5 dpa at 300°C. The post-irradiation experiments using Small Specimen Test Technology included hardness, tensile, and fracture mechanics tests combined with fractography and microstructure analysis are presented. Results show that micro-alloying EUROFER97-type steels influenced the mechanical properties but a dominating impact on irradiation damage resistance could not be identified. In contrast, specific thermo-mechanical treatments lead to better DBTT behavior. Discussion about irradiation response to heat treatment conditions is also given. Here, despite requiring data also at high dpa values, the results indicate that with these modified materials an increased lifetime and potentially also an increased operating temperature window can be achieved compared to EUROFER97.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Very high cycle fatigue characteristics of laser beam powder bed fused AlSi10Mg: A systematic evaluation of part geometry

This study explores the influence of geometry and part size on defect distribution, melt pool size, and mechanical characteristics in laser beam powder bed fused (LB-PBF) AlSi10Mg. Five distinct geometries—hourglass, small rod, small block, large block, and large rod—were fabricated under identical process parameters. Fully reversed ultrasonic fatigue testing, operating at a frequency of 20 kHz, was conducted to assess the very high cycle fatigue properties. The findings indicated that part geometry had a major impact on the fatigue properties of the material in the very high cycle fatigue regime. Specimens machined from large rods and large blocks had the lowest porosity and highest fatigue resistance. Microstructural analysis indicated that hourglass, small rod, and small block specimens had shallower melt pools and overlap depths compared to other geometries. This observation suggests a higher cooling rate in specimens with smaller cross-sectional areas, leading to the increased presence of entrapped gas pores and a lack of fusion defects. Understanding the relationship between part geometry and fatigue properties in LB-PBF components offers insights for optimizing design and manufacturing processes in additive manufacturing applications.

AlSi10Mg↗
DOE OSTI2025

High-temperature stability and thermal expansion behavior of equi-atomic refractory multi-principal element alloys based on MoNbTi system for Gen IV reactor applications

The present study investigates the thermal stability and thermal expansion behavior of seven equi-atomic refractory multi-principal element alloys (MPEAs) based on the MoNbTi ternary system composed of low neutron absorption cross section elements. Through an integrated approach utilizing in-situ high-temperature X-ray diffraction (HT-XRD) in conjunction with differential scanning calorimetry (DSC), dilatometry and ageing heat treatment, the thermal stability of the MPEAs was comprehensively analyzed. In-situ HT-XRD experiment confirmed the stability of the room temperature phases up to 1000 °C with no peaks observed corresponding to additional phases in the HT-XRD patterns at 500, 800 and 1100 °C. DSC thermograms showed the absence of peaks up to 1000 °C, while peaks and valleys corresponding to exothermic and endothermic events were observed above 1000 °C. Coefficient of thermal expansion (CTE) derived from second order polynomial fitting of linear thermal expansion data from the dilatometry experiment showed linear increment up to 1000 °C for all the alloys except those containing Zr. The Cr containing alloys exhibited notably higher CTE values, particularly the Al containing alloy exhibited the highest value. Ageing heat treatment at 800 and 1000 °C for 96 h and subsequent microstructural analysis revealed significant precipitation of secondary phases in MoNbTiZr, MoNbTiZrV and MoNbTiCrAl. In conclusion, a substantial increase in hardness was observed in MoNbTiZr and MoNbTiCrAl due to secondary phase precipitation, while the other alloys maintained hardness values comparable to their as-cast and homogenized states.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2019

Temperature and load-ratio dependent fatigue-crack growth in the CrMnFeCoNi high-entropy alloy

Multiple-principal element alloys known as high-entropy alloys have significantly been gaining attention for the vast variety of compositions and potential combinations of properties that remain to be explored. Of these alloys, one of the earliest, the ‘Cantor alloy’ CrMnFeCoNi, demonstrates excellent damage-tolerance with tensile strengths of ~1 GPa and fracture toughness values in excess of 200 MPa√m; moreover, these mechanical properties tend to further improve at cryogenic temperatures. Yet, few studies have explored its corresponding fatigue properties. Here we expand on our previous study to examine the mechanics and mechanisms of fatigue-crack propagation in the CrMnFeCoNi alloy (~7 μm grain size), with emphasis on long-life, near-threshold fatigue behavior, specifically as a function of load ratio at temperatures between ambient and liquid-nitrogen temperatures (293 K–77 K). We discover that Δ K th fatigue thresholds are decreased with increasing positive load ratios, $\mathcal{R}$ between 0.1 and 0.7, but are increased at decreasing temperature. These effects can be attributed to the role of roughness-induced crack closure, which was estimated using compliance measurements. Evidence of deformation twinning at the crack tip during fatigue-crack advance was not apparent at ambient temperatures but seen at higher stress intensities (Δ K ~ 20 MPa√m) at 77 K by post mortem microstructural analysis for tests at $\mathcal{R}$ = 0.1 and particularly at 0.7. Overall, the fatigue behavior of this alloy was found to be superior, or at least comparable, to conventional cryogenic and TWIP steels such as 304 L or 316 L steels and Fe-Mn steels; these results coupled with the remarkable strength and fracture toughness of the Cantor alloy at low temperatures indicate significant promise for the utility of this material for applications at cryogenic environments.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Characterization of fusion welded ceramics in the SiC-ZrB 2 -ZrC system

Various SiC-ZrB 2 -ZrC ceramics were joined by fusion welding to determine the maximum silicon carbide content that could be joined. Commercial powders were hot pressed, machined, and preheated to 1450 °C before joining with a tungsten inert gas welding torch at 160–200 A. Resulting welds were cross-sectioned and analyzed to determine which compositions were weldable and to characterize microstructural evolution in welded samples. As compositions approached the ternary eutectic, the welds had smaller SiC grains and exhibited better weldability. Penetration depth of welds was controlled by a combination of current input and welding speed. Here, the ternary eutectic in the system was found at 36.9 ± 1.3 vol% SiC, 42.7 ± 1.5 vol% ZrB 2 , and 20.4 ± 1.9 vol% ZrC and its melting temperature was 2330 ± 23 °C. A ternary phase diagram for the SiC-ZrB 2 -ZrC was constructed and proposed via microstructural analysis of arc melted pellets on binary joins between each binary eutectic and the ternary eutectic in the system.

36 MATERIALS SCIENCE↗
DOE OSTI2026

A Novel Surface Restoration Method for Hydropower Steel Components: Plasma Gouging and Inconel Cold Spray Coating for Material Repair

A novel surface restoration approach combining plasma gouging with subsequent cold spray deposition is demonstrated in this study. Plasma gouging effectively removes the damaged steel surface, leaving grooves and forming a plasma gouging affected zone up to ~300?µm thick. Within this zone, a hardened martensitic layer with a peak hardness of ~370?HV—almost twice that of the base substrate (~200?HV)—is produced. Following plasma gouging, cold spray deposition is applied to rebuild the surface. Experimental results reveal that cold spray coatings deposited at low energy suffer from delamination, whereas high energy cold spray deposits yield a well-bonded coating. Microstructural analysis further shows that the martensitic layer formed by plasma gouging undergoes dynamic recrystallization during cold spray, reducing the hardness to 317?HV. These findings demonstrate the feasibility of this hybrid method for effective surface restoration of damaged steel components.

Wang, Tianhao↗
DOE OSTI2022

Stress-controlled fatigue of HfNbTaTiZr high-entropy alloy and associated deformation and fracture mechanisms

The stress-controlled fatigue tests are carried out at a stress ratio of 0.1 and a frequency of 10 Hz, and span both low-cycle and high-cycle regimes by varying the applied stress amplitudes. The high-cycle fatigue regime gives a fatigue strength of 497 MPa and a fatigue ratio of 0.44. At equivalent conditions, the alloy's fatigue strength is greater than all other high-entropy alloys (HEAs) with reported high-cycle fatigue data, dilute body-centered cubic alloys, and many structural alloys such as steels, titanium alloys, and aluminum alloys. Through in-depth analyses of crack-propagation trajectories, fracture-surface morphologies and deformation plasticity by means of various microstructural analysis techniques and theoretical frameworks, the alloy's remarkable fatigue resistance is attributed to delayed crack initiation in the high-cycle regime, which is achieved by retarding the formation of localized persistent slip bands, and its good resistance to crack propagation in the low-cycle regime, which is accomplished by intrinsic toughening backed up by extrinsic toughening. Additionally, the stochastic nature of the fatigue data is neatly captured with a 2-parameter Weibull model.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Diffusion behaviors between metallic fuel alloys with Pd addition and Fe

Fission product lanthanides (Lns) in metallic fuel is the primary cause of fuel-cladding chemical interaction (FCCI). Palladium (Pd) is being explored as a potential additive to reduce or mitigate FCCI by forming stable Pd-Ln compounds. The current study is an investigation of diffusion behaviors between UZrPd, UZrPdLn, UPuZrPd, and UPuZrPdLn alloys (Ln = 53Nd-25Ce-16Pr-6La wt. %) and iron (Fe). Diffusion couple tests were performed followed by microstructural analysis using scanning electron microscopy (SEM) and transmission electron microscopy (TEM). It is found that the diffusion of Fe into the fuel is reduced by PdZr2 precipitates randomly dispersed throughout the fuel matrix. Ln-Pd compounds form in UZrPdLn alloys, and (Ln,Pu)Pd forms in the UPuZrPdLn alloy. In both diffusion couples with Ln, small amounts of Lns are diffusing into the Fe. This could be due to small amounts of dissolved Lns in the precipitates, or could be due to the Ln-Pd compounds decomposing. In either case, diffusion caused by Lns is greatly reduced.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Microstructure and diffusion behavior of uranium fuel with minor additives

Fission product lanthanides in metallic fuels are known to cause adverse fuel-cladding chemical interaction (FCCI). Tin (Sn) and palladium (Pd) are being explored as the potential additives to reduce or mitigate lanthanide-induced FCCI by forming stable Sn-Ln and Pd-Ln compounds. The current study is an investigation of the fuel alloys, U–4Sn, U–4Sn-4Ln, U–4Pd, and U–4Pd-4Ln (wt. %), and their diffusion behaviors with Fe. Microstructural analysis was performed using scanning electron microscopy (SEM). Further, the binary phases in the UPd and USn alloys are identified as UPd 3 and suspected U 2 Sn, where U 2 Sn is unknown in the literature. The binary phases in the UPdLn alloy are identified as PdLn and Pd-rich Pd-Ln (Pd 4 Ln 3 and Pd 3 Ln 2 ), and in the USnLn alloy is SnLn. Diffusion of Fe with these binary phases is insignificant compared to the diffusion with U. The Ln-induced FCCI can be mitigated by the additives.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

High-temperature steam oxidation study of irradiated FeCrAl defueled specimens

Post irradiation examinations (PIE) were performed on irradiated iron-chromium-aluminum (FeCrAl) specimens. These FeCrAl specimens were fabricated at the US Department of Energy's Oak Ridge National Laboratory (ORNL). The experimental setup involved subjecting FeCrAl cladding, along with UO 2 pellets, to irradiation in the Idaho National Laboratory Advanced Test Reactor (ATR). In parallel, the FeCrAl alloy tubing without UO 2 pellets was irradiated at ORNL's High Flux Isotope Reactor (HFIR). After irradiation, the ATR-irradiated rodlet was transported to an ORNL hot cell, where it was sectioned into multiple samples for the PIE and severe-accident testing. The sectioning process revealed that the fuel was not bonded to the cladding and could be easily detached from sectioned cladding slices. Microstructural analysis of the fuel cross sections demonstrated no significant interaction between the fuel and the cladding. Additionally, high-temperature steam oxidation tests on defueled cladding segments showed minimal oxygen uptake even at 1200 °C. Here, the ATR-irradiated specimens began to exhibit signs of enhanced oxidation upon reaching a temperature of 1300 °C. Furthermore, enhanced oxidation was observed on the inner surface of the ATR-irradiated FeCrAl specimen, which had been subjected to 1300 °C for a duration of 1 min. By contrast, high-temperature steam oxidation experiments indicated that the HFIR-irradiated FeCrAl cladding provided good thermal stability when exposed to 1300 °C for up to 4 h. Comparative analysis encompassing the oxidation behavior of the ATR-irradiated fueled FeCrAl, HFIR-irradiated unfueled FeCrAl, and unirradiated FeCrAl suggests that the fuel–cladding interaction, although not visible via standard microscale electron microscopy measurements, may accelerate the deterioration of FeCrAl cladding in beyond-design-basis accident scenarios.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Manufacturing Oxide Dispersion Strengthened (ODS) steel plate via cold spray and friction stir processing

Oxide dispersion strengthened (ODS) steels, traditionally fabricated by ball milling and conventional powder metallurgy techniques to achieve bulk form, followed by intricate rolling and thermal treatment steps to achieve plate or sheet form. Here, we present a novel processing route that combines cold spray (CS) with friction stir processing (FSP) to manufacture ODS steel plate directly from gas atomization reaction synthesis (GARS)-prepared powder, thus no rolling steps involved. Microstructural and mechanical characterizations were performed to assess the quality and properties of the resulting ODS steel plate. Our findings demonstrate that the slightly porous CS deposited layer was fully consolidated after FSP, yielding a fully dense ODS steel plate that exhibited a favorable tradeoff between strength and ductility upon extraction from the substrate. Furthermore, through microstructural analysis, we revealed the presence of an appreciable density (∼10 22 /m 3 ) of nano-sized oxide particles, with the majority being smaller than 5 nm via the combined CS + FSP fabrication route. This work serves as a first proof-of-concept demonstration of the manufacturing approach described herein, offering a possible alternative route for producing ODS steel plates.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Microstructural evolution in doped high entropy alloys NiCoFeCr-3X (X=Pd/Al/Cu) under irradiation

Commonly studied equatomic single-phase FCC high entropy alloys based on 3d transition metals like NiCoFeCr do not provide adequate strength and radiation resistance at high doses for nuclear structural applications. In the current study, the major alloying effects like lattice distortion, ordering and clustering tendencies were investigated by adding low concentration of Pd, Al, or Cu respectively to study the doping effects on the ion irradiation response of NiCoFeCr alloy. The alloys were irradiated with 3 MeV Ni 2+ ions at 500 °C to a fluence of 1 × 10 17 /cm 2 at a beam flux of approximately 2.8 × 10 12 ions/cm 2 /s. The microstructural evolution upon irradiation i.e., formation of dislocation networks, radiation induced segregation and precipitation, and void formation were studied in detail. Further, post-irradiation characterization results showed that a Pd addition leads to a high void nucleation rate but controlled void growth, which may be attributed to increased lattice distortion. In Al added HEA, our microstructural analysis indicates that radiation induced ordered L1 2 precipitates do not affect void swelling significantly. Cu addition led to Cu precipitation that drastically suppressed dislocation density and void swelling of the alloy. Additionally, a model was developed to qualitatively describe the trend in void swelling of typical FCC alloys under ion irradiation. This model was able to qualitatively explain the suppression and reappearance of void swelling in ion irradiated alloys that generally occurs near the region with peak implanted ion concentration.

36 MATERIALS SCIENCE↗
DOE OSTI2012

Compliant alkali silicate sealing glass for solid oxide fuel cell applications: the effect of protective YSZ coating on electrical stability in dual environment

Recently, compliant sealing glass has been proposed as a potential candidate sealant for solid oxide fuel cell (SOFC) applications. In a previous paper, the thermal stability and chemical compatibility were reported for a compliant alkali-containing silicate glass sealed between anode supported YSZ bi-layer and YSZ-coated stainless steel interconnect. In this paper, we will report the electrical stability of the compliant glass under a DC load and dual environment at 700-800 degrees C. Apparent electrical resistivity was measured with a 4-point method for the glass sealed between two plain SS441 metal coupons or YSZ-coated aluminized substrates. The results showed instability with plain SS441 at 800 degrees C, but stable behavior of increasing resistivity with time was observed with the YSZ coated SS441. In addition, results of interfacial microstructure analysis with scanning electron microscopy will be correlated with the measured resistivity results. Overall, the YSZ coating demonstrated chemically stability with the alkali-containing compliant silicate sealing glass under electrical field and dual environments.

coating↗
DOE OSTI2020

Effect of binder on the overcharge response in LiFePO 4 -containing cells

Two types of small pouch cells based on LiFePO 4 /graphite, one containing a N-methyl pyrrolidinone (NMP)-soluble binder, poly(vinylidene difluoride), and the other an aqueous-soluble binder, styrene-butadiene rubber/carboxymethylcellulose were systematically charged to 100, 120, 140, 160, 180, and 250% state of charge (SOC). The cells were then discharged to 3.0 V at room temperature before being disassembled for postmortem analysis. Microstructural changes in the anode associated with increasing SOC were more pronounced in the aqueous processed cells in comparison to the NMP-processed cells. Dendrite formation was observed on the aqueous-processed anode at 120% SOC, while the NMP-processed anode surface does not show dendrites until 250% SOC. Overall, the aqueous-processed anode surfaces displayed more evidence of microstructural degradation as a function of increasing SOC. In the NMP-processed cells, four organic compounds on the anode surface were found to show a dependence on SOC, while only two displayed a similar dependency in the aqueous-processed cells. The nature of the binder changed the number and composition of the species found at the anode.

25 ENERGY STORAGE↗