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375 records · Page 21
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Fatigue performance of laser powder bed fusion hydride-dehydride Ti-6Al-4V powder

We report hydride-dehydride (HDH) Ti-6Al-4V alloy with particle size distribution of 50–120 µm is laser powder bed fusion (L-PBF) processed using optimum processing parameters and a near-fully dense structure with a density of 99.9 % is achieved. Microstructural observations and phase analyses indicate formation of columnar β grains with acicular α/α' phases in as-built condition. The roughness of the as-fabricated samples is significant with an average roughness of R a = 15.71 ± 3.96 µm and a root mean square roughness of R rms = 108.4 ± 24.9 µm, however, both values are reduced to R a = 0.19 ± 0.04 µm and R rms = 4.9 ± 0.6 µm after mechanical grinding. Mechanical tests are carried out on as-fabricated specimens followed by stress relief treatment. All samples are tested to failure in fatigue, under fully-reversed tension-compression conditions of R = –1. The as-built samples failed from the surface with crack initiation mainly at micro-notches, whereas after mechanically grinding, crack initiation changed to subsurface defects such as pores. Minimizing surface roughness by mechanically grinding eliminates surface micro-notches which improves fatigue strength in the high cycle fatigue region. Fatigue notch factor calculations showed that the effect of surface roughness was significantly lower when HDH powder is used compared to standard spherical powder. X-ray diffraction analysis revealed an in-plane compressive stress, micro-strain and grain refinement on the surface of the mechanically ground samples. Fractography observations (macroscale) revealed a fully brittle fracture in the first stage of crack growth with a transition to a dominantly ductile fracture in the third stage of crack growth. On the other hand, at the micro scale, even the brittle fracture regions showed evidence of ductile fracture within the α' martensite laths.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Cryo-STEM Tomography with Inpainting

Traditionally, microscopists have worked with the Nyquist-Shannon theory of sampling, which states that to be able to reconstruct the image fully it needs to be sampled at a rate of at least twice the highest spatial frequency in the image. This sampling rate assumes that the image is sampled at regular intervals and that every pixel contains information that is crucial for the image (it even assumes that noise is important). Images in general, and especially low dose S/TEM images, contain significantly less information than can be encoded by a grid of pixels (which is why image compression works). Mathematically speaking, the image data has a low dimensional or sparse representation. Through the application of compressive sensing methods [1,2,3] this representation can be found using pre-designed measurements that are usually random for implementation simplicity. These measurements and the compressive sensing reconstruction algorithms have the added benefit of reducing noise. This reconstruction approach can be extended into higher dimensions, whereby the random sampling in each 2-D image can be extended into: a sequence of tomographic projections (i.e. tilt images); a sequence of video frames (i.e. incorporating temporal resolution and dynamics); spectral resolution (i.e. energy filtering an image to see the distribution of elements); and ptychography (i.e. sampling a full diffraction image at each location in a 2-D grid across the sample). This approach has been employed experimentally for materials science samples requiring low-dose imaging [2], and can be readily applied to biological samples. Figure 1 shows the resolution possible in a complex biological system, mouse pancreatic islet beta cells [4], when tomogram slices are reconstructed using subsampling. Reducing the number of pixels (1/6 pix and 1/3*1/3) shows minimal degradation compared to the reconstructions using all pixels (all data and 1/3 tilt). Although subsampling 1/6 of the tilts (1/6 of overall dose) degrades the reconstruction to the point that the cellular structures cannot be identified. Using 1/3 of both the pixels and the tilts provides a high quality image at 1/9 the overall dose even for this most basic and rapid demonstration of the CS methods. Figure 2 demonstrates the theoretical tomogram reconstruction quality (vertical axis) as undersampling (horizontal axis) is increased; we examined subsampling pixels and tilt-angles individually and a combined approach in which both pixels and tilts are sub-sampled. Note that subsampling pixels maintains high quality reconstructions (solid lines). Using the inpainting algorithm to obtain tomograms can automatically reduce the dose applied to the system by an order of magnitude. Perhaps the best way to understand the impact is to consider that by using inpainting (and with minimal hardware changes), a sample that can normally withstand a dose of ~10 e/Å2 can potentially be imaged with an “equivalent quality” to a dose level of 103 e/Å2. To put this in perspective, this is approaching the dose level used for the most advanced images, in terms of spatial resolution, for inorganic systems. While there are issues for biological specimens beyond dose (structural complexity being the most important one), this sampling approach allows the methods that are traditionally used for materials science to be applied to biological systems [5]. References: [1] A Stevens, H Yang, L Carin et al. Microscopy 63(1), (2014), pp. 41. [2] L Kovarik, A Stevens, A Liyu et al. Appl. Phys. Lett. 109, 164102 (2016) [3] A Stevens, L Kovarik, P Abellan et al. Adv. Structural and Chemical Imaging 1(10), (2015), pp. 1. [4] MD Guay, W Czaja, MA Aronova et al. Scientific Reports 6, 27614 (2016) [5] Supported by the Chemical Imaging, Signature Discovery, and Analytics in Motion Initiatives at PNNL. PNNL is operated by Battelle Memorial Inst. for the US DOE; contract DE-AC05-76RL01830.

Stevens, Andrew↗
DOE OSTI2016

Irradiation in the Swiss Spallation Neutron Source and its Applications

In high power (∼ 1 MW or higher) spallation targets being operated or developed for different attractive applications such as neutron scattering science and technology or accelerator driven systems (ADS) for nuclear waste transmutation, both target and structural materials are exposed to intensive irradiation of high energy protons and spallation neutrons. Since spallation reactions induced by high energy protons can produce helium (He) and hydrogen (H) and other transmutation elements at very high rates, the behavior of materials used in a spallation irradiation environment can be much different from those observed from materials irradiated with neutrons in fission reactors. Therefore, the damage induced by spallation irradiation cannot be simply simulated by fission neutron irradiation experiments. Seven irradiation experiments have been conducted in the targets of the Swiss Spallation Neutron Source (SINQ) at the Paul Scherrer Institute (PSI) since 1998 within a broad international collaboration with Commissariat a L'energie Atomique Centre d'Etudes de Saclay (CEA), Forschungszentrum Juelich (FZJ), Japan Atomic Energy Agency (JAEA), Los Alamos National Laboratory (LANL), Oak Ridge National Laboratory (ORNL), University California Santa Barbara (UCSB) and several institutes of Chinese Academy of Sciences. More than 7000 samples from various Al-, Ti-, Fe-, Ni-, Zr-, and W-alloys and SiC/SiC, C/SiC and MAX-phase ceramics composites have been irradiated to doses up to ∼25 dpa (in Fe) and ∼2000 appm He at temperatures up to ∼800 deg. C. In addition, quite many specimens were irradiated in contact with stagnant liquid metals such as Hg, PbBi, PbLi etc. Dedicated post-irradiation examinations (PIE) have been performed, together with the international collaborators. Various mechanical tests including tensile, bend, Charpy-impact, small punch and hardness have been carried out to obtain the mechanical properties of the materials after irradiation. The microstructural changes in the irradiated specimens have been investigated by means of transmission electron microscopy, positron annihilation spectroscopy, atom probe tomography etc. Many novel results have been obtained from the PIE conducted by PSI and other STIP partner laboratories. The DBTT-shift of different FM steels increases more or less linearly with dose after irradiation in the SINQ target, while it saturates at a level of few dpa in fission neutron irradiation cases. This phenomenon can be mostly attributed to helium effects. In addition to the strong embrittlement effect, pronounced hardening effect was also detected in high dose specimens, which was contributed by high density helium bubbles.

36 MATERIALS SCIENCE↗
DOE OSTI2019

The effects of carbon on the phase stability and mechanical properties of heat-treated FeNiMnCrAl high entropy alloys

This work systematically investigates the effect of carbon on the phase stability and room- temperature tensile performance of an annealed Fe 40.4 Ni 11.3 Mn 34.8 Al 7.5 Cr 6 (at%) high entropy alloy without (HEA) and with 1.1% carbon (CHEA). Four annealing conditions were investigated: 773 K for 13 d and 42 d, 973 K for 20 d, and 1073 K and 1423 K for 24 h. The resulting microstructures were analyzed using a combination of scanning electron microscopy (SEM), transmission electron microscopy (TEM), energy dispersive spectroscopy (EDS), and atom probe tomography (APT). Vickers hardness testing and room- temperature tensile testing were used to determine the mechanical properties of the annealed HEA and the CHEA. APT composition profiles revealed fine Ni,Mn,Al-enriched matrix precipitates in the CHEA annealed at 773 K for 13 d. After ageing at 773 K for 42 d, colonies of (Ni,Fe) 2 MnAl- enriched Heusler phase lamellae were observed at the grain boundaries (GBs) and in the matrix for the HEA, while GB lamellar colonies of Mn,Cr-enriched M 23 C 6 carbides were observed for the CHEA. Due to the presence of the GB carbides, the resulting room-temperature elongation to fracture for the CHEA annealed at 773 K for 42 d was ~1% compared to ~11% for the HEA given the same anneal. At higher annealing temperatures, the microstructure contains Ni,Al-rich and Mn,Cr,C-rich precipitates that alternate along the GBs and appear to be associated with each other in the matrix. Electron diffraction analysis indicates the aforementioned Ni,Al-precipitates and Mn,Cr-carbides have b.c.c. and f.c.c. crystal structures, respectively. Once again, a low elongation to fracture (2%) was seen for the carbon-containing material compared to its un-doped counterpart (23%) which solely contained Ni,Al-rich b.c.c. precipitates.

36 MATERIALS SCIENCE↗
DOE OSTI2018

A consistent path for phase determination based on transmission electron microscopy techniques and supporting simulations

Here this work addresses aspects for the analysis of industrial relevant materials via transmission electron microscopy (TEM). The complex phase chemistry and structural diversity of these materials require several characterization techniques to be employed simultaneously; unfortunately, different characterization techniques often lack connection to yield a complete and consistent picture. This paper describes a continuous path, starting with the acquisition of 3D diffraction data – alongside classical high-resolution imaging techniques – and linking the structural characterization of hard metal industrial samples with energy-loss fine-structure simulations, quantitative electron energy-loss (EEL) and energy-dispersive X-ray (EDX) spectroscopy. Thereby, the compositional analysis of a MAX phase indicated an offset of the hydrogenic, theoretical sensitivity factors, originating from poorly-adjusted screening factors. In a next step, these results were matched against quantitative compositions and parameters obtained from X-ray spectroscopy data, carried out synchronously with EELS.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Growth, electrical, structural, and magnetic properties of half-Heusler CoT i 1 - x F e x Sb

Epitaxial thin films of the substitutionally alloyed half-Heusler series CoTi 1-x Fe x Sb were grown by molecular beam epitaxy on InAlAs/InP(001) substrates for concentrations 0.0 ≤ x ≤ 1.0. The influence of Fe on the structural, electronic, and magnetic properties was studied and compared to that expected from density functional theory. The films are epitaxial and single crystalline, as measured by reflection high-energy electron diffraction and X-ray diffraction. Using in-situ X-ray photoelectron spectroscopy, only small changes in the valence band are detected for x ≤ 0.5. For films with x ≥ 0.05, ferromagnetism is observed in SQUID magnetometry with a saturation magnetization that scales linearly with Fe content. A dramatic decrease in the magnetic moment per formula unit occurs when the Fe is substitutionally alloyed on the Co site indicating a strong dependence on the magnetic moment with site occupancy. A crossover from both in-plane and out-of-plane magnetic moments to only in-plane moment occurs for higher concentrations of Fe. Ferromagnetic resonance indicates a transition from weak to strong interaction with a reduction in inhomogeneous broadening as Fe content is increased. Temperature-dependent transport reveals a semiconductor to metal transition with thermally activated behavior for x ≤ 0.5. Anomalous Hall effect and large negative magnetoresistance (up to -18.5% at 100 kOe for x=0.3) are observed for higher Fe content films. Evidence of superparamagnetism for x=0.3 and x=0.2 suggests for moderate levels of Fe, demixing of the CoTi 1-x Fe x Sb films into Fe rich and Fe deficient regions may be present. Atom probe tomography is used to examine the Fe distribution in a x=0.3 film. Finally, statistical analysis reveals a nonhomogeneous distribution of Fe atoms throughout the film, which is used to explain the observed magnetic and electrical behavior.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Lattice distortion in a strong and ductile refractory high-entropy alloy

Here, the maximization of the mixing entropy with the optimal range of enthalpy in high-entropy alloys (HEAs) can promote the formation of a stable single solid-solution phase with the absence of competing intermetallic compounds. The resultant effects, such as lattice distortion, can contribute to excellent mechanical properties, which has motivated numerous efforts to develop and design single-phase HEAs. However, challenges still remain, particularly on quantifying the lattice distortion and relating it to materials properties. In this study, we have developed a NbTaTiV refractory HEA with a single body-centered-cubic (BCC) structure using an integrated experimental and theoretical approach. The theoretical efforts include thermodynamic modeling, i.e., CALculation of PHAse Diagram (CALPHAD). The microstructural evolutions have been investigated by systematic heat-treatment processes. The typical dendrite microstructure was observed, which is caused by the elemental segregation during the solidification in the as-cast condition. The structural inhomogeneity and chemical segregation were completely eliminated by the proper homogenization treatment at 1200 °C for 3 days. The homogeneous elemental distribution was quantitatively verified by the Atom Probe Tomography (APT) technique. Importantly, results indicate that this HEA exhibits the high yield strength and ductility at both room and high temperatures (up to 900 °C). Furthermore, the effects of the high mixing entropy on the mechanical properties are discussed and quantified in terms of lattice distortions and interatomic interactions of the NbTaTiV HEA via first-principles calculations. It is found that the local severe lattice distortions are induced, due to the atomic interactions and atomic-size mismatch in the homogenization-treated NbTaTiV refractory HEA.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Microstructure and coercivity in alnico 9

Magnetic property enhancement of alnico, a rare-earth free permanent magnet, is highly dependent on both the initial microstructure and the evolution of the spinodal decomposition (SD) inside each grain during the heat treatment process. The size, shape and distribution of the magnetic FeCo-rich (α 1 ) phase embedded in continuous non-magnetic AlNi-rich (α 2 ) phase as well as a minor Cu-enriched phase residing in between are shown to be crucial in controlling coercivity. Phase and magnetic domain morphology in a commercial alnico 9 alloy was studied using a combination of structural characterization techniques, including scanning electron microscopy, electron backscatter diffraction, aberration-corrected scanning transmission electron microscopy and Lorentz microscopy. Our results showed that casting created structural nonuniformity and defects, such as porosity, TiS 2 precipitates and grain misorientation, are heterogeneously distributed, with the center section having the best crystallographic orientation and minimal defects. The optimal spinodal is a “mosaic structure”, composed of rod-shape α1 phase with {110} or {100} planar faceting and diameter of ~30–45nm. There is also a Cu-enriched phase residing at the corners of two < 110 > facets of the α1 phase. Furthermore, it was observed that grain boundary phase reverse magnetization direction at lower external magnetic field compared to the SD region inside the grain. Improving grain orientation uniformity, reducing detrimental grain boundary phase volume fraction, and the branching of the α 1 rods, as well as their diameter, are promising routes to improve energy product of alnico.

36 MATERIALS SCIENCE↗
DOE OSTI2022

On the high-temperature stability of the Al 8 Cu 3 Ce intermetallic in an additively manufactured Al-Cu-Ce-Zr alloy

High-temperature resistant eutectic Al alloys are crucial materials for lightweight and energy efficient design in the automotive and aviation industries. Additive manufacturing offers a pathway to refine eutectic microstructures and develop novel alloys with superior high-temperature strength. High-volume fraction intermetallic Al-Cu-Ce alloys have been developed to deliver high-temperature strength in combination with reduced hot-tearing susceptibility. Zr is added to provide additional strengthening via nanoscale Al 3 Zr precipitation, and to stabilize and avoid coarsening of the Al 8 Cu 3 Ce phase. However, the detailed interaction between Zr and Al 8 Cu 3 Ce remains unexplored. In this work, we show with synchrotron X-ray diffraction that laser powder bed fusion fabricated Al-Cu-Ce and Al-Cu-Ce-Zr alloys contain predominantly the Al 8 Cu 3 Ce intermetallic in the as-fabricated condition. Heat treatment of the Al-Cu-Ce alloy results in the Al 8 Cu 3 Ce → Al 8 Cu 4 Ce phase transformation. In the Al-Cu-Ce-Zr alloy, minor fractions of (Al,Cu,Si) 4 Ce and Al 2 Cu-θ are found in the as-fabricated condition, while Al 8 Cu 3 Ce remains stable during heat treatment. Atom probe microscopy quantifies intermetallic stoichiometries and reveals how Zr is enriched at the Al-matrix/Al 8 Cu 3 Ce interface acting as a diffusion barrier against solute exchange. Calibrated thermodynamic modeling underpins this as a kinetic effect. Here, a qualitative microstructural model summarizes, how Zr stabilizes Al 8 Cu 3 Ce against phase transformations and coarsening.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Imaging in 3D under pressure: a decade of high-pressure X-ray microtomography development at GSECARS

The high-pressure X-ray microtomography (HPXMT) apparatus has been operating at the GeoSoilEnviroCARS (GSECARS) bending magnet beamline at the Advanced Photon Source since 2005. By combining the powerful synchrotron X-ray source and fast switching between white (for X-ray diffraction) and monochromatic (for absorption imaging) modes, this technique provides the high-pressure community with a unique opportunity to image the three-dimensional volume, texture, and microstructure of materials under high pressure and temperature. The ability to shear the sample with unlimited strain by twisting the two opposed anvils in the apparatus allows shear deformation studies under extreme pressure and temperature to be performed. HPXMT is a powerful tool for studying the physical properties of both crystalline and non-crystalline materials under high pressure and high temperature. Over the past 10 years, continuous effort has been put into technical development, modifications to improve the overall performance, and additional probing techniques to meet users’ needs. Here in this paper, we present an up-to-date report on the HPXMT system, a brief review of some of its many exciting scientific applications, and a discussion of future developments.

47 OTHER INSTRUMENTATION↗
DOE OSTI2020

Second Annual Progress Report on Correlation Between Microstructure and Mechanical Properties of Neutron-Irradiated Ferritic-Martensitic and Austenitic Steels

Ferritic-martensitic steels G92-2b (an optimized Grade 92 heat), NF616 and T91, and austenitic stainless steel 800H and its Grain Boundary Engineering (GBE)-treated version 800H-TMP (ThermoMechanical Processing) were irradiated in the High Flux Isotope Reactor (HFIR) of Oak Ridge National Laboratory (ORNL) and the Advanced Test Reactor (ATR) of Idaho National Laboratory (INL). Selected G92-2b samples were irradiated up to 14.66 dpa in the HFIR at two temperature ranges: 400–496.7°C and 683.3– 720°C. NF616 and T91 were irradiated in the ATR up to 8.16 dpa with the irradiation temperatures ranged from 241°C to 447.5°C. Alloy 800H and 800H-TMP samples were irradiated in both the HFIR and the ATR. Selected 800H and 800H-TMP samples had HFIR irradiation to 1.28 dpa at 580°C and ATR irradiation up to 9.12 dpa at 359°C to 431°C. Vickers hardness measurements, fractography, and microstructural characterization were performed on the selected samples in the Low Activation Materials Design and Analysis (LAMDA) laboratory. Radiation-hardening of G92-2b was observed at the lower doses and lower irradiation temperatures (400- 496.7°C), with GB03 (0.52 dpa at 400°C) and GB04 (7.44 dpa at ~490°C) showing ~12% and ~8% hardening, respectively. Softening by ~14% was observed for GB05 (14.66 dpa at 496.7°C). Radiationsoftening of G92-2b was more prevalent at the higher irradiation temperatures (683.3-~720°C), with GB10 (0.46 dpa at 683.3°C), GB11 (7.44 dpa at ~720°C), and GB12 (14.63 dpa at ~720°C) showing ~8%, ~8%, and ~40% softening, respectively. Radiation-hardening of NF616 and T91 was observed with the hardness increased by ~37% to ~65% depending on the irradiation doses and irradiation temperatures. Within the studied irradiation conditions of NF616 and T91, samples with a higher dose had a larger hardness after irradiation. All the tested alloy 800H and 800H-TMP samples in this work showed radiation-hardening by ~96±7% to ~152±10%. Alloy 800H-TMP tended to have slightly smaller radiation-hardening than alloy 800H. The fractography results of G92-2b sample GB03, GB10, and GB11, together with the previously characterized fractography of GB04, GB05, and GB12, indicated that the ductility of G92-2b was maintained up to 14.66 dpa at the lower irradiation temperatures of 400-496.7°C, while some loss of ductility (less necking) was observed for higher doses at the higher irradiation temperatures of 683.3-720°C. This agrees with the previously reported tensile test results of G92-2b, where the elongation of G92-2b was reduced at higher doses at the higher irradiation temperatures. Dimple sizes increased at higher doses, which are more evident at the higher irradiation temperatures of 683.3-~720°C. The fractography of NF616 sample D2 (2.96 dpa at 291.5°C), D4 (5.91 dpa at 359°C), and D6 (8.16 dpa at 431°C) indicated loss of ductility with negligible necking for sample D2, while ductile failure for samples D4 and D6. Fractography of alloy 800H and 800H-TMP samples in various irradiation conditions showed ductile failure with obvious necking. Dimples were observed, with some of them containing large Ti-rich particles, in all the 800H/800H-TMP samples. Electron backscatter diffraction characterization of GB12 indicated the recovery of the lath structure, which was generally replaced by an equiaxed grain structure. Transmission electron microscopy (TEM) characterization showed the presence of frequent M 23 C 6 (M = primarily Cr), MX (M = primarily V), spherical Nb(C,N) precipitates, and occasional Laves phase precipitates in the G92-2b samples. MX precipitates with sizes of 20-30 nm were observed at boundaries of smaller grains, indicating the pinning effect of the V-rich precipitates. The lath structure recovery was more evident at the higher irradiation temperatures (683.3-~720°C), with decreased densities of line dislocations and M23C6 precipitates. The irradiated T91 (TA04) showed the growth of M23C6 precipitates to 101 ± 40 nm from the initial 68 ± 22 nm in the unirradiated condition. Dislocation loops of both {100} and {111} types were present in TA04. TEM characterization was also performed on the irradiated 800H (N4, N5, N6, and AR2) and 800H-TMP (P4, P5, P6, and HG1). Accumulation of M 23 C 6 precipitates at grain boundaries was observed in all the xii 800H/800H-TMP samples, and the presence of Ti(C,N) precipitates at grain boundaries and in the matrix was observed in the irradiated 800H-TMP. Some Ti(C,N) precipitates are embedded in the M 23 C 6 precipitates, maintaining specific orientation relationships between the precipitates and between the precipitate and matrix. In addition, nanoscale Si-rich clusters were observed in the matrix of all the 800H/800H-TMP samples, with EDS Si maps tending to have a lower contrast in 800H-TMP samples. Atom probe tomography was conducted on the same samples, supported by a Rapid Turnaround Examination project under Nuclear Science User Facilities. The results are being analyzed to be integrated with the TEM results for a confident description of the γ’ precipitates. Dislocation loops also formed in all the 800H/800H-TMP samples. The density and the average size of dislocation loops were quantified to be in the order of 10 22 – 10 23 m -3 and 11.7 – 15.9 nm, respectively, in the ATR-irradiated 800H/800H-TMP samples. The loop densities in irradiated 800H were higher than that in irradiated 800H-TMP under the same irradiation conditions. Further systematic data analyses, together with some complementary experiments, will be pursued for these samples to foster peer-reviewed journal article publications.

36 MATERIALS SCIENCE↗
DOE OSTI2020

First Examination of Irradiated Fuel with Pulsed Neutrons at LANSCE (Preliminary Results)

We present preliminary results on the characterization of an irradiated U-lOZr-lPd fuel sample that was prepared from the irradiated AFC-3A-R5A sample. U-lOZr metallic fuels are researched as host materials for potential transmutation fuels and the addition of palladium strives to bind lanthanides, thus preventing fuel-cladding chemical interactions (FCCI). These interactions limit the lifetime of metallic fuels and are caused by migration of lanthanide fission products to the periphery of the fuel slug, where they start to interact with the D9 or HT9 steel cladding, ultimately leading to failure of the mechanical integrity of the cladding. Neutrons offer bulk characterization of irradiated materials for which X-ray tomography methods are not suitable due to the immense gamma background emitted from the samples. In particular pulsed neutrons provide information from the ability to resolve the neutron energy using their time-of-flight and thus the potential to utilize neutron absorption resonance to characterize the spatial distribution of isotopes. This, in turn, may allow to characterize the distribution of fission and neutron capture products non-destructively and may ultimately be applied to the bulk of an irradiation capsule prior to destructive post-irradiation examination to identify regions of interest. To allow the characterization of entire irradiation capsules, a cask is under development in the advanced post-irradiation work package at LANL and progress on this development was reported elsewhere. In parallel, an irradiated U-lOZr-lPd sample cut from the AFC-3AR5A irradiation was shipped to LANL and will be fully characterized with an NSUF funded rapid turnaround experiment (RTE) in the 2020 LANSCE run cycle. The sample emits at a dose rate of ~3R/hr on contact and is therefore manageable with remote handling, without requiring a cask. The disk-shaped material is larger than samples prepared for analysis using electron or X-ray methods and is therefore an intermediate step towards characterization of bulk samples at LANSCE. However, since it covers the full diameter of the irradiated fuel slug, some insight on redistribution of elements, spatially resolved information on microstructure, e.g. phase composition and texture, will be possible using the pulsed neutron-based methods developed for fuel characterization at LANSCE. This report describes the development of procedures to handle the sample at LANSCE as well as preliminary data and results from tests conducted in December 2019 on the energy-resolved neutron imaging (ERNI) beam line at flight path 5 and the high pressure-preferred orientation diffractometer (HIPPO) at LANSCE. This effort is a collaboration between LANL, INL, and ORNL. To compare our capabilities with prior work, we present an overview of previously reported bulk characterization of irradiated or spent fuels. The overview addresses neutron diffraction and neutron absorption resonance spectroscopy, both of which have only few reported applications on irradiated or spent nuclear fuel, as well as neutron radiography. This literature review was already described in a previous report but is repeated here to put our current efforts in context of previous work.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Subgrain geometrically necessary dislocation density mapping in spalled Ta in three dimensions

Here, in this work, the intragranular distributions of the densities of geometrically necessary dislocations (GNDs) generated in a polycrystalline tantalum (Ta) sample loaded in shock compression to spall are investigated. The sample studied is a highly resolved three-dimensional (3D) map of the orientations, grain boundary morphology, and voids across a 0.276mm 3 (with sample dimensions of 688.5µm x 669µm x 600µm) region of the microstructure about the spall plane obtained by TriBeam tomography. We present a formulation for calculating the crystallographic screw and edge character GND densities at a material point within body centered cubic (BCC) crystals when provided any number of potential slip systems or modes. Combining the 3D characterization, GND formulation, and a sample containing ≈ 6000 grains, we sought statistically relevant correlations between GND density per grain with grain size, grain orientation, void formation, and proximity from the spall plane. We show that GND density per grain increases with decreasing distance from the spall plane. Most grains had heterogeneously distributed GND densities but were free of any detectable voids, at least within the ≈ 1.5µm resolution of the characterization technique. It is found that the GND density for most grains is insensitive to grain size and grain orientation. Only the fraction of grains with the highest GND densities tended to have a [001] parallel to shock-direction orientation. Intragranular 3D maps of GNDs reveals that grains that contain voids have high GND density concentrations in the intragranular region immediately surrounding the void. The local intragranular GND mapping also showed voids that are connected to grain boundaries preferred to grow into the grain with the larger size, regardless of orientation.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Cathode Upcycling for Direct Recycling of Lithium‐Ion Batteries Using a Precipitation Approach

With the increased production of electric vehicles to reduce carbon emissions, the lithium-ion battery market to supply those vehicles has grown dramatically. To enhance battery sustainability and circularity, direct recycling methods aim to recover intact cathode materials. However, end-of-life cathode materials are typically 15–20 years old and often have lower energy density compared to current cathode materials. To address this challenge, a rapid precipitation process is developed to boost energy density by converting low Ni-compositions, LiNi 0.33 Co 0.33 Mn 0.33 O 2 (NMC111), into higher Ni-compositions (NMC622). This process forms a Ni-rich coating on cathode particles that diffuses into the core upon high-temperature relithiation, increasing compositional homogeneity. The upcycling process leverages existing infrastructure, offering low capital cost and minimal additional chemical input. Through ex situ tomographic transmission X-ray microscopy (TXM), 3D Ni:Co elemental mixing is quantified, confirming that elemental content evens at the secondary particle level with a mean NMC622 composition upon relithiation. However, elemental gradients remain in the single crystalline primary particles. Ex situ high-resolution and in situ wide-angle X-ray diffraction reveals concurrent structural changes during the relithiation process. These findings provide key insights into the structural and chemical mechanisms of elemental diffusion to obtain further improvements of increased capacity and retention through compositional conversion of cathode materials.

Cathode Upcycling↗
DOE OSTI2016

TH-AB-209-07: High Resolution X-Ray-Induced Acoustic Computed Tomography

Purpose: X-ray radiographic absorption imaging is an invaluable tool in medical diagnostics, biology and materials science. However, the use of conventional CT is limited by two factors: the detection sensitivity to weak absorption material and the radiation dose from CT scanning. The purpose of this study is to explore X-ray induced acoustic computed tomography (XACT), a new imaging modality, which combines X-ray absorption contrast and high ultrasonic resolution to address these challenges. Methods: First, theoretical models was built to analyze the XACT sensitivity to X-ray absorption and calculate the minimal radiation dose in XACT imaging. Then, an XACT system comprised of an ultrashort X-ray pulse, a low noise ultrasound detector and a signal acquisition system was built to evaluate the X-ray induced acoustic signal generation. A piece of chicken bone and a phantom with two golden fiducial markers were exposed to 270 kVp X-ray source with 60 ns exposure time, and the X-ray induced acoustic signal was received by a 2.25MHz ultrasound transducer in 200 positions. XACT images were reconstructed by a filtered back-projection algorithm. Results: The theoretical analysis shows that X-ray induced acoustic signals have 100% relative sensitivity to X-ray absorption, but not to X-ray scattering. Applying this innovative technology to breast imaging, we can reduce radiation dose by a factor of 50 compared with newly FDA approved breast CT. The reconstructed images of chicken bone and golden fiducial marker phantom reveal that the spatial resolution of the built XACT system is 350µm. Conclusion: In XACT, the imaging sensitivity to X-ray absorption is improved and the imaging dose is dramatically reduced by using ultrashort pulsed X-ray. Taking advantage of the high ultrasonic resolution, we can also perform 3D imaging with a single X-ray pulse. This new modality has the potential to revolutionize x-ray imaging applications in medicine and biology.

60 APPLIED LIFE SCIENCES↗