Search NASA⌕ Search

SEARCH · Search NASA

Results for “AM Powder Characterization”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 415 records · Page 23
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Γ-brasses in the Mn-Zn system: An experimental and computational study

Here, the synthesis and characterization of Ni 2 Zn 11 -type γ-brasses with composition Mn 2+x Zn 11–x (x = 0.06–0.60) are reported. The synthesis follows standard high temperature methods and characterization by single crystal X-ray diffraction (SCXRD) and powder X-ray Diffraction (PXRD) techniques as well as Energy Dispersive Spectroscopy (EDS). First principles electronic structure calculations showed preferential heteroatomic Mn–Zn bonding and repulsive effects of Zn–Zn 3 d –3 d orbital overlap that influence the metal atom distribution in the structure. Local bonding environments and the relationship of Mn 2+x Zn 11-x to other γ-brasses containing 3 d metals such as PdCoZn 11 and Ni 2 Zn 11 are discussed.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Influence of heterocyclic N-donors on the structural topologies and vibrational spectra of uranyl selenate phases

Uranyl (U(VI)O 2 2+ ) selenate compounds represent a well-studied family of structures with diverse structural arrays. Differences in the overall topology and bonding with the uranyl cation combined with additional intermolecular interactions can lead to variation in the resulting spectroscopic signals. Here, in the current study, we evaluated the structural chemistry and vibrational spectroscopy for uranyl selenates crystallized with heterocyclic N-donors. Five compounds ((C 4 H 12 N 2 )[(UO 2 )(SeO 4 ) 2 (H 2 O)]·H 2 O (USe_pip), (C 4 H 5 N 2 ) 2 [(UO 2 )(SeO 4 ) 2 (H 2 O)] (USe_pyrdz), (C 5 H 5 N) 2 [(UO 2 ) 2 (SeO 4 ) 3 (H 2 O)] ∙ 3H 2 O (USe_pyrmd), (H 3 O) 2 (C 4 H 5 N 2 ) 2 [(UO 2 ) 3 (SeO 4 ) 5 (H 2 O)]·H 2 O (USe_pyrz), and (C 5 H 6 N) 2 [(UO 2 ) 2 (SeO 4 ) 3 (H 2 O)] ∙ 3H 2 O (USe_pyr)) were characterized using X-ray diffraction (single-crystal and powder) and vibrational (Raman and IR) spectroscopy. Two one-dimensional (1-D) chain and three two-dimensional sheet (2-D) topologies were identified and classified based upon previous graphical representations. Overall, the arrangement of the heteroatoms could be linked to the hydrogen bonding network associated with the heterocycles and selenate anions. Vibrational spectra of the solid-state compounds were complex, with multiple bands associated with the uranyl cation, selenate anion, and heteroatoms. The ν 1 symmetric stretching band of the uranyl was relatively consistent across all compounds, whereas differences were observed for the ν 3 asymmetric band between the 1-D and 2-D structural topologies.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2018

Microstructure, precipitates and hardness of selectively laser melted AlSi10Mg alloy before and after heat treatment

Highlights: • Microstructural characterization of SLM AlSi10Mg alloy and comparison with cast and powder AlSi10Mg • Effect of solution heat treatment and aging on the hardness change of SLM AlSi10Mg alloy • Evolution of strengthening precipitates and Fe-rich intermetallics in SLM AlSi10Mg during heat treatment - Abstract: The microstructure and precipitates within selectively laser melted (SLM) AlSi10Mg alloys in the as-built state and after T6 heat treatment were examined and correlated to the hardness evolution. The as-built alloy exhibited columnar patterns perpendicular to the build-direction and fish-scale pattern along the build-direction originating from the melt pool. The microstructure consisted of fine Al cells and eutectic structure with up to 4 μm in size. Tiny needle-like Si particles with highly faulted structure were identified within the Al cells and formed semi-coherent interface with the matrix. Nanoscale Si particles and π-Al{sub 8}Si{sub 6}Mg{sub 3}Fe phase were observed to segregate along the cell and grain boundary. Solution heat treatment (SHT) at 520 °C resulted in the dissolution of Al cellular microstructure. Precipitation and coarsening of the Si particles occurred, while the aspect ratio of Si particles remained nearly constant. The π-Al{sub 8}Si{sub 6}Mg{sub 3}Fe phase decomposed into plate-shaped β-Al{sub 5}SiFe. The artificial aging (AA) at 160 °C did not alter the microstructure but led to the formation of metastable Mg{sub 2}Si precipitates. The GP zones and β″ were identified through transmission electron microscopy after AA of 6 h, and β″ existed up to AA of 24 h. The hardness decreased after SHT due to the coarsening of the microstructure and reduced solid solution hardening. Hardness reached maximum magnitude after AA of 6–10 h due to the precipitation hardening, and remained relatively unchanged up to AA of 24 h. Microstructure and/or hardness of gas atomized powders and bulk cast AlSi10Mg alloys were also examined as references.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Novel amorphous SiOC dispersion-strengthened austenitic steels.

Here, a novel amorphous silicon oxycarbide dispersion-strengthened (SiOC-DS) austenitic steel has been fabricated via a powder metallurgy process. The microstructure of dispersion particles has been characterized by transmission electron microscopy (TEM) and electron backscatter diffraction (EBSD), revealing that amorphous SiOC nanoparticles with an average particle size of 30 nm were homogeneously distributed in the austenite grains with a sub-micrometer grain size. The high strength and hardness of SiOC-DS may be attributed to grain boundary strengthening, as well as dispersion strengthening via dislocation–particle interactions that were revealed by TEM investigations. In situ ion irradiation experiments showed that amorphous SiOC particles were stable after irradiation of 3.7 dpa, and the SiOC/steel interface can be an effective sink for the annihilation of irradiation defects. The excellent mechanical and irradiation properties of SiOC-DS austenitic steel make it a promising structural material for nuclear applications.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Silver Sulfide and Silver Sulfate as Aging Byproducts and Adsorbents for Gaseous Iodine Capture in Spent Nuclear Fuel Reprocessing

While it is considered a promising adsorbent for radioiodine capture in spent nuclear fuel reprocessing off-gas, silver functionalized silica aerogel (Ag 0 -aerogel) experiences a capacity loss when exposed to other off-gas components (O 2 , H 2 O, NO, and NO 2 ) through a process known as aging. Ag 2 S and Ag 2 SO 4 were identified as major byproducts of aging, but their impact on iodine adsorption remains unclear. Thus, to further investigate aging, we loaded Ag 2 S and Ag 2 SO 4 powders with molecular iodine (I 2 ) at 150 °C and characterized their properties. The I 2 adsorption capacity of Ag 2 SO 4 was 0.12 wt % after 72 h, suggesting its formation directly reduces the capacity of the Ag 0 -aerogel. Conversely, Ag 2 S had an iodine capacity of 86.8 wt % and near total Ag utilization after 240 h. Given its high capacity and availability, we evaluated the feasibility of Ag 2 S as an I 2 adsorbent in future applications. Finally, several drawbacks need to be overcome, including the relatively slow uptake rate, potential emission of another hazardous byproduct (SO 2 ), and potential aging effects (e.g., Ag 2 S conversion to Ag 2 SO 4 ) before Ag 2 S can be applied for the radioiodine capture process.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Scalable Synthesis and Characterization of Multilayer γ-Graphyne, New Carbon Crystals with a Small Direct Band Gap

γ-Graphyne is the most symmetric sp 2 /sp 1 allotrope of carbon, which can be viewed as graphene uniformly expanded through the insertion of two-carbon acetylenic units between all the aromatic rings. To date, synthesis of bulk γ-graphyne has remained a challenge. In this work, we report the synthesis of multilayer γ-graphyne through crystallization-assisted irreversible cross-coupling polymerization. A comprehensive characterization of this new carbon phase is described, including synchrotron powder X-ray diffraction, electron diffraction, lateral force microscopy, Raman spectroscopy, infrared spectroscopy, and cyclic voltammetry. Experiments indicate that γ-graphyne is a 0.48 eV band gap semiconductor, with a hexagonal a-axis spacing of 6.88 Å and an interlayer spacing of 3.48 Å, which is consistent with theoretical predictions. The observed crystal structure has an aperiodic sheet stacking. The material is thermally stable up to 240 °C but undergoes transformation at higher temperatures. While conventional 2D polymerization and reticular chemistry rely on error correction through reversibility, we demonstrate that a periodic covalent lattice can be synthesized under purely kinetic control. The reported methodology is scalable and inspires extension to other allotropes of the graphyne family.

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

Embedding thermocouples in SS316 with laser powder bed fusion

Recent advances in manufacturing technologies have enabled the fabrication of complex geometries for a wide range of applications, including the energy, aerospace, and civil sectors. The ability to integrate sensors at critical locations within these complex components during the manufacturing process could benefit process monitoring and control by reducing reliance on models to relate surface measurements to internal phenomena. This study investigated embedding thermocouples in a SS316 matrix using laser powder bed fusion. Under optimal processing conditions, embedded thermocouples were characterized post-building, finding good bonding to the matrix with no melt pool penetration to the sensing elements. Futher, the embedded thermocouple performed similarly to an identical non-embedded thermocouple during thermal testing to 500 °C with only a slight difference in response time, which was attributed to the differences in mass and the associated thermal time constants.

image analysis↗
DOE OSTI2021

Biosurfactant production by halophilic yeasts isolated from extreme environments in Botswana

ABSTRACT Nine morphologically distinct halophilic yeasts were isolated from Makgadikgadi and Sua pans, as pristine and extreme environments in Botswana. Screening for biosurfactant production showed that Rhodotorula mucilaginosa SP6 and Debaryomyces hansenii MK9 exhibited the highest biosurfactant activity using Xanthocercis zambesiaca seed powder as a novel and alternative inexpensive carbon substrate. Chemical characterization of the purified biosurfactants by Fourier Transform Infra-Red spectroscopy suggested that the biosurfactant from R. mucilaginosa SP6 was a rhamnolipid-type whereas the biosurfactant from D. hansenii MK9 was a sophorolipid-type. The two biosurfactants exhibited antimicrobial activities against eight pathogenic bacteria and fungal strains (Proteus vulgaris, Escherichia coli, Klebsiella pneumoniae, Staphylococcus aureus, Micrococcus luteus, Cryptococcus neoformans, Candida albicans and Aspergilus niger). The sophorolopid-type biosurfactant was found to be the most potent among the antimicrobial drug resistant strains tested. The findings open up prospects for the development of environmentally friendly antimicrobial drugs that use an inexpensive source of carbon to reduce the costs associated with the production of biosurfactants.

Loeto, Daniel↗
DOE OSTI2020

Synthesis and Flash Sintering of (Hf1-xZrx)B2 Solid Solution Fine Powders

Fine powders of (Hf1-xZrx)B2 solid solution were synthesized by two methods. In the first one, solution-based processing of HfCl4, ZrCl4, sucrose and H3BO3 was carried out followed by heat treatment (e.g., at 1500 °C for 1 h) in Argon to achieve the carbothermal reduction (CTR) reaction to form the boride solid solution. In the second one, called boron hydride reduction (BHR) method, HfCl4, ZrCl4 and NaBH4 were directly mixed in a glove box followed by heat treatment in Argon at elevated temperatures from 700 to 1500 °C. In addition, the powders synthesized via both methods were flash sintered without sample preheating in a homemade setup. The synthesized powders as well as the flash sintered bulk ceramics were characterized using different techniques including XRD, SEM, EDS, TEM, TGA-DSC, and Vickers hardness test to reveal the inter-relationships between starting materials composition, processing conditions, and the resulting materials microstructure and physical/chemical properties.

Belisario, Jose↗
DOE OSTI2020

Technology Enabling Zero-EPZ Micro Modular Reactors: Fabrication of Zirconium Hydride with Controlled Hydrogen Loading

This report completes Milestone M2.2.2 - ZrH pellet fabricated with controlled hydride loading: ZrH1.5±0.1 single phase pellets fabricated with controlled and thermally stable hydride loading. Hydrogen content to be quantified and single-phase confirmed by X-ray diffraction. In this milestone, we report the successful fabrication of delta-phase zirconium hydride pellets using the ORNL bulk metal hydriding system. The successful deployment of zirconium hydride moderator in advanced reactors requires development of a consistent and affordable production pathway along with implementation of a hydrogen retention solution throughout the reactor life. Fabrication of delta-phase zirconium hydride is challenging since the absorption of a large amount of hydrogen into alpha-zirconium induces significant volume expansion and the present hydrogen concentration gradient results in cracking. A fully programmable hydriding system with continuous hydrogen partial pressure and flow control to facilitate processing of massive metal hydride has been developed at ORNL. In this report, the working principle of the hydriding system will be introduced. Characterization of the produced zirconium hydride includes X-ray powder diffraction to identify the present phases and X-ray Computed Tomography to visualize the internal microstructure (including cracks). The results indicate that single delta-phase zirconium hydride pellets with various sizes have been successfully produced.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Mechanical and Tribological Performance of Additively Manufactured Nanocrystalline Aluminum via Cryomilling and Cold Spray

In this study, nanocrystalline (NC) aluminum (Al) and magnesium (Mg)-doped Al bulk components were fabricated using a hybrid manufacturing process that combines cryomilling and high-pressure cold spray (HPCS) additive deposition techniques. Yttria-stabilized zirconia (YSZ) was also added during the HPCS process to improve deposition efficiency and build-up thickness via peening. The evolution of morphology, crystallite size, and elemental composition of both cryomilled powders and cold-sprayed (CS’ed) components was systematically characterized using X-ray Diffraction (XRD), Scanning Electron Microscopy (SEM), and Transmission Electron Microscopy (TEM). Mechanical characterization was performed using Vickers microhardness and uniaxial tensile testing, while the tribological behavior was assessed using sliding wear tests under dry/lubricated conditions. XRD analysis revealed that increased cryomilling duration led to significant crystallite refinement, which directly correlated with enhanced hardness and strength. This mechanical strengthening was accompanied by an increase in coefficient of friction (COF) and lower wear rates. The results also showed that the Mg-doped Al exhibited superior hardness, tensile strength, and tribological performance compared to pure Al. The study further explores the underlying mechanisms responsible for these enhancements, highlighting the potential of solute-assisted grain boundary stabilization in tailoring high-performance NC Al alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2019

On the Feasibility of Tailoring Copper–Nickel Functionally Graded Materials Fabricated through Laser Metal Deposition

In this study, pulse-width modulation of laser power was identified as a feasible means for varying the chemical gradient in copper–nickel-graded materials. Graded material deposits of 70 wt. %. copper-30 wt. %. nickel on 100 wt. %. nickel and vice versa were deposited and characterized. The 70/30 copper–nickel weight ratio in the feedstock powder was achieved through blending elemental copper and 96 wt. %. Ni–Delero-22 alloy. At the dissimilar material interface over the course of four layers, the duty cycle of power was ramped down from a high value to optimized deposition conditions. This change was theorized to influence the remelting and deposition height, and by extension, vary the chemistry gradient. X-ray Energy Dispersive Spectroscopy (EDS) analysis showed significant differences in the span and nature of chemistry gradient with varying duty cycles. These observations were also supported by the variation in microhardness values across the interface. The influence of different chemistry gradients on the tensile performance was observed through mini-tensile testing, coupled with Digital Image Correlation (DIC). The strain fields from the DIC analysis showed variations in strain for different chemistry gradients. The strength measurements from these specimens were also different for different chemistry gradients. The site of failure was observed to always occur within the copper-rich region.

36 MATERIALS SCIENCE↗
NASA NTRS1978

Interaction of hydrogen chloride with alumina

The influence of temperature, pressure, and outgas conditions on the absorption of hydrogen chloride and water vapor on both alpha and gamma alumina was studied. Characterization of the adsorbents was performed using X-ray powder diffraction, scanning electron microscopy (SEM), low temperature nitrogen adsorption desorption measurements, BET nitrogen surface area measurements and electron spectroscopy for chemical analysis (ESCA). Water vapor adsorption isotherms at 30, 40, and 50 C were measured on alpha and gamma alumina after outgassing at 80, 200, and 400 C. Both outgas temperature and adsorption temperature influenced the adsorption of water vapor on the aluminas. The water vapor adsorption was completely reversible. Alpha alumina absorbed more water per unit area than gamma alumina. Differences in the adsorption capacity for water vapor of the two aluminas were explained on the basis of ideal surface models of alpha and gamma alumina. Isosteric heats of adsorption for water vapor on the aluminas were determined over a limited range of surface coverage.

Bailey, R. R.↗
NASA NTRS1986

Correlation of processing and sintering variables with the strength and radiography of silicon nitride

A sintered Si3N4-SiO2-Y2O3 composition, NASA 6Y, was developed that reached four-point flexural average strength/standard deviation values of 857/36, 544/33, and 462/59 MPa at room temperature, 1200 and 1370 C respectively. These strengths represented improvements of 56, 38, and 21 percent over baseline properties at the three test temperatures. At room temperature the standard deviation was reduced by over a factor of three. These accomplishments were realized by the iterative utilization of conventional x-radiography to characterize structural (density) uniformity as affected by systematic changes in powder processing and sintering parameters. Accompanying the improvement in mechanical properties was a change in the type of flaw causing failure from a pore to a large columnar beta- Si3N4 grain typically 40 to 80 microns long, 10 to 30 microns wide, and with an aspect ratio of 5:1.

Sanders, W. A.↗
NASA NTRS1986

Correlation of processing and sintering variables with the strength and radiography of silicon nitride

A sintered Si3N4-SiO2-Y2O3 composition, NASA 6Y, was developed that reached four-point flexural average strength/standard deviation values of 857/36, 544/33, and 462/59 MPa at room temperature, 1200 and 1370 C, respectively. These strengths represented improvements of 56, 38, and 21 percent over baseline properties at the three test temperatures. At room temperature the standard deviation was reduced by over a factor of three. These accomplishments were realized by the iterative utilization of conventional X-radiography to characterize structural (density) uniformity as affected by systematic changes in powder processing and sintering parameters. Accompanying the improvement in mechanical properties was a change in the type of flaw causing failure from a pore to a large columnar beta-Si3N4 grain typically 40-80 micron long, 10-30 micron wide, and with an aspect ratio of 5:1.

Sanders, W. A.↗
NASA NTRS1986

Improved processing of Si3N4

A sintered Si3N4-SiO2-Y2O3 composition, NASA 6Y, was developed that reached four-point flexural average strength/standard deviation values of 857/36, 544/33, and 462/59 MPa at room temperature, 1200, and 1370 C, respectively. These strengths represented improvements of 56, 38, and 21 percent over baseline properties at the three test temperatures. At room temperature the standard deviation was reduced by more than a factor of three. These accomplishments were realized by the iterative utilization of conventional X-radiography to characterize structural (density) uniformity as affected by systematic changes in powder processing and sintering parameters. Accompanying the improvement in mechanical properties was a change in the type of flaw causing failure from a pore to a large columnar beta-Si3N4 grain typically 40 to 80 microns, 10 to 30 microns wide, and with an aspect ratio of 5:1.

Sanders, William A.↗
NASA NTRS1990

Lead-ruthenium pyrochlores as oxygen electrocatalysts

An investigation of lead-ruthenium pyrochlores of the structure Pb2(Ru/2-x/Pb/x/) O7-y for use as oxygen electrocatalysts in alkaline media is discussed. Lead-ruthenium pyrochlore mixed metal oxides were prepared and characterized by X-ray diffraction, BET surface area, dry powder conductivity, and chemical stability. Gas diffusion electrodes were developed specifically for the lead-ruthenium pyrochlore materials. Also investigated were the effects of varying electrode fabrication parameters on the oxygen reduction performance of the lead-ruthenium pyrochlore electrocatalyst. Long-term stability performance was also evaluated. The oxygen reduction performance of the pyrochlore electrocatalyst is considerably higher than that of the state-of-the-art gold-platinum alloy electrocatalyst currently used by NASA. Furthermore, the pyrochlore electrocatalysts are attractive candidates for high-performance pressurized alkaline fuel cells.

Anderson, E. B.↗