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DOE OSTI2015

Microstructural characterisation of friction stir welding joints of mild steel to Ni-based alloy 625

In this study, 6-mm-thick mild steel and Ni-based alloy 625 plates were friction stir welded using a tool rotational speed of 300 rpm and a travel speed of 100 mm·min{sup −1}. A microstructural characterisation of the dissimilar butt joint was performed using optical microscopy, scanning and transmission electron microscopy, and energy dispersive X-ray spectroscopy (XEDS). Six different weld zones were found. In the steel, the heat-affected zone (HAZ) was divided into three zones and was composed of ferrite, pearlite colonies with different morphologies, degenerated regions of pearlite and allotriomorphic and Widmanstätten ferrite. The stir zone (SZ) of the steel showed a coarse microstructure consisting of allotriomorphic and Widmanstätten ferrite, degenerate pearlite and MA constituents. In the Ni-based alloy 625, the thermo-mechanically affected zone (TMAZ) showed deformed grains and redistribution of precipitates. In the SZ, the high deformation and temperature produced a recrystallised microstructure, as well as fracture and redistribution of MC precipitates. The M{sub 23}C{sub 6} precipitates, present in the base material, were also redistributed in the stir zone of the Ni-based alloy. TMAZ in the steel and HAZ in the Ni-based alloy could not be identified. The main restorative mechanisms were discontinuous dynamic recrystallisation in the steel, and discontinuous and continuous dynamic recrystallisation in the Ni-based alloy. The interface region between the steel and the Ni-based alloy showed a fcc microstructure with NbC carbides and an average length of 2.0 μm. - Highlights: • Comprehensive microstructural characterisation of dissimilar joints of mild steel to Ni-based alloy • Friction stir welding of joints of mild steel to Ni-based alloy 625 produces sound welds. • The interface region showed deformed and recrystallised fcc grains with NbC carbides and a length of 2.0 μm.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Hemicellulose Modulates Nanoscale Lignin Architecture in Synthetic Plant Cell Walls

Cellulose, hemicellulose, and lignin─the most abundant biopolymers on Earth─compose the structural matrix of plant biomass, providing renewable resources critical to bioenergy and sustainable materials. Despite their importance, the nanoscale mechanochemical processes underlying lignocellulose assembly during plant secondary cell wall formation remain poorly understood, hindering advancements in biomass conversion technologies. Here, in this study, we synthesize a biomimetic model system comprising cellulose–hemicellulose nanofibrils (CHN) to examine guaiacyl lignin polymerization in a physiologically relevant context. Using advanced nanocharacterization─scattering-type scanning near-field optical microscopy (s-SNOM) with infrared nanospectroscopy coupled to solid-state nuclear magnetic resonance (NMR)─we reveal that hemicellulose presence considerably modulates lignin deposition and alters its interunit bond distribution. Specifically, hemicellulose-rich environments dramatically reduce lignin deposition by approximately 50% and yield highly condensed lignin structures characterized by severely reduced β–O–4′ linkages (<2%) and suppressed β–β′ linkages. Conversely, cellulose-alone scaffolds support notably higher β–O–4′ content (∼10%), resulting in a more uniform nanoscale lignin coating. Our work helps explain how accessible hemicellulose sites, both sterically and chemically, direct radical coupling during lignification, fundamentally reshaping lignin’s nanoscale architecture. These findings deepen our mechanistic understanding of plant cell wall biosynthesis and inform strategies aimed at enhancing biomass deconstruction efficiency for sustainable bioenergy applications.

NMR↗

DOE OSTI2014

Microstructures of ancient and modern cast silver–copper alloys

The microstructures of modern cast Sterling silver and of cast silver objects about 2500 years old have been compared using optical microscopy (OM), scanning electron microscopy (SEM), transmission electron microscopy (TEM), scanning transmission electron microscopy (STEM), energy dispersive X-ray microanalysis (EDX) and electron backscatter diffraction (EBSD). Microstructures of both ancient and modern alloys were typified by silver-rich dendrites with a few pools of eutectic and occasional cuprite particles with an oxidised rim on the outer surface. EBSD showed the dendrites to have a complex internal structure, often involving extensive twinning. There was copious intragranular precipitation within the dendrites, in the form of very fine copper-rich rods which TEM, X-ray diffraction (XRD), SEM and STEM suggest to be of a metastable face-centred-cubic (FCC) phase with a cube–cube orientation relationship to the silver-rich matrix but a higher silver content than the copper-rich β in the eutectic. Samples from ancient objects displayed a wider range of microstructures including a fine scale interpenetration of the adjoining grains not seen in the modern material. Although this study found no unambiguous evidence that this resulted from microstructural change produced over archaeological time, the copper supersaturation remaining after intragranular precipitation suggests that such changes, previously proposed for wrought and annealed material, may indeed occur in ancient silver castings. - Highlights: • Similar twinned structures and oxidised surfaces seen in ancient and modern cast silver • General precipitation of fine Cu-rich rods apparently formed by discontinuous precipitation is characteristic of as-cast silver. • The fine rods are cube-cube related to the matrix in contrast with the eutectic. • The silver-rich phase remains supersaturated with copper. • Possibly age-related grain boundary features seen in ancient cast silver.

36 MATERIALS SCIENCE↗

DOE OSTI2011

Microstructure, mechanical properties and texture evolution of AZ31 alloy containing trace levels of strontium

The effect of low levels of Sr (0.01, 0.03, 0.05 wt.%) on the microstructure, mechanical properties and texture of AZ31 magnesium alloy has been investigated. Thermodynamic modeling has been used to study the effect of Sr on phase precipitation at different temperatures. Cooling curve analysis reveals a decrease in solidification superheat with the addition of 0.03 wt.% Sr to AZ31. The as-cast microstructures of the alloys have been studied using optical microscopy (OM) and electron probe micro analysis (EPMA). Results show the refining effect of Sr on the grain size and on the {beta}-Mg{sub 17}Al{sub 12} precipitates through growth poisoning and inoculation, respectively. To investigate the mechanical properties of the alloys, as-cast samples were compression tested at elevated temperatures. Hot compression peak stress ({sigma}{sub max}) and critical strain before recrystallization ({epsilon}{sub c}) initially drop but then increase. {sigma}{sub max} first decreases due to the depletion of Al from solid solution and then increases when the amount of the Al-Sr precipitates reach a significant amount. {epsilon}{sub c} drops due to the acceleration of dynamic recrystallization kinetics as a result of grain refinement. It increases with increasing Sr when the concentration Sr in solid solution is increased leading to dislocation pinning and retardation of recrystallization. X-ray texture measurements on the hot compressed and extruded samples show a decrease in maximum intensity of the basal pole figures with increasing Sr as a result of reduced twining and the changes in Al and Sr concentrations in solid solution. - Research Highlights: {yields} Microstructures/precipitates of AZ31+trace levels of Sr were examined by OM and EPMA. {yields} Thermodynamic calculations and cooling curve analysis were used to predict ppt formation. {yields} It has been shown that Sr refines the grains and Mg17Al12 precipitates. {yields} Mechanical properties and texture were studied using hot compression and X-ray diffraction. {yields} Different micro-mechanisms were responsible for mechanical and texture changes.

36 MATERIALS SCIENCE↗

DOE OSTI2014

Effects of rare earth yttrium on microstructure and properties of Ni–16Mo–7Cr–4Fe nickel-based superalloy

Effects of rare earth yttrium on microstructure of Ni–16Mo–7Cr–4Fe alloy were examined by optical microscopy, scanning electron microscopy, transmission electron microscopy and X-ray fluorescence. M{sub 6}C phase was observed in the alloys with and without yttrium addition, and Ni{sub 17}Y{sub 2} phase existed in the alloys containing 0.05–0.43 wt.% yttrium simultaneously. The amount of Ni{sub 17}Y{sub 2} phase increased as yttrium concentration increased. When the concentration of yttrium increased to 0.43 wt.%, some multi-precipitated phase regions appeared in the form of large amount of coarse Ni{sub 3}Y phase surrounded by M{sub 6}C phase and γ phase in the alloy. Influences of rare earth yttrium on high temperature static oxidation and mechanical properties of Ni–16Mo–7Cr–4Fe alloy were also investigated. The alloy containing 0.05 wt.% yttrium showed the best oxidation resistance and mechanical properties simultaneously. The adequate concentration of yttrium at grain boundary and in the solid-solution (γ phase) and the adhesion enhancement of the outer oxidation scale to the substrate are key factors for the improvements in the mechanical properties and oxidation resistance respectively. - Highlights: • When the content of yttrium reaches to 0.43%, some multiphase regions appear. • When the content of yttrium reaches to 0.43%, some Ni{sub 17}Y{sub 2} chains appear. • The morphology of M{sub 6}C changes with increasing concentration of yttrium. • The Ni–16Mo–7Cr–4Fe alloy with 0.05% yttrium performs the best mechanical property. • The Ni–16Mo–7Cr–4Fe alloy with 0.05% yttrium performs the best oxidation resistance.

36 MATERIALS SCIENCE↗

DOE OSTI2014

Effects of metallic nanoparticle doped flux on the interfacial intermetallic compounds between lead-free solder ball and copper substrate

Lead free solders currently in use are prone to develop thick interfacial intermetallic compound layers with rough morphology which are detrimental to the long term solder joint reliability. A novel method has been developed to control the morphology and growth of intermetallic compound layers between lead-free Sn–3.0Ag–0.5Cu solder ball and copper substrate by doping a water soluble flux with metallic nanoparticles. Four types of metallic nanoparticles (nickel, cobalt, molybdenum and titanium) were used to investigate their effects on the wetting behavior and interfacial microstructural evaluations after reflow. Nanoparticles were dispersed manually with a water soluble flux and the resulting nanoparticle doped flux was placed on copper substrate. Lead-free Sn–3.0Ag–0.5Cu solder balls of diameter 0.45 mm were placed on top of the flux and were reflowed at a peak temperature of 240 °C for 45 s. Angle of contact, wetting area and interfacial microstructure were studied by optical microscopy, field emission scanning electron microscopy and energy-dispersive X-ray spectroscopy. It was observed that the angle of contact increased and wetting area decreased with the addition of cobalt, molybdenum and titanium nanoparticles to flux. On the other hand, wettability improved with the addition of nickel nanoparticles. Cross-sectional micrographs revealed that both nickel and cobalt nanoparticle doping transformed the morphology of Cu{sub 6}Sn{sub 5} from a typical scallop type to a planer one and reduced the intermetallic compound thickness under optimum condition. These effects were suggested to be related to in-situ interfacial alloying at the interface during reflow. The minimum amount of nanoparticles required to produce the planer morphology was found to be 0.1 wt.% for both nickel and cobalt. Molybdenum and titanium nanoparticles neither appear to undergo alloying during reflow nor have any influence at the solder/substrate interfacial reaction. Thus, doping of flux with appropriate metallic nanoparticles can be successfully used to control the morphology and growth of intermetallic compound layers at the solder/substrate interface which is expected to lead to better reliability of electronic devices. - Highlights: • A novel nanodoped flux method has been developed to control the growth of IMCs. • Ni doped flux improves the wettability, but Co, Mo and Ti deteriorate it. • Ni and Co doped flux gives planer IMC morphology through in-situ alloying effect. • 0.1 wt.% Ni and Co addition into flux gives the lowest interfacial IMC thickness. • Mo and Ti doped flux does not have any influence at the interfacial reaction.

36 MATERIALS SCIENCE↗

DOE OSTI2016

Correlative characterization of primary particles formed in as-cast Al-Mg alloy containing a high level of Sc

Primary particles formed in as-cast Al-5Mg-0.6Sc alloy and their role in microstructure and mechanical properties of the alloy were investigated using optical microscopy (OM), scanning electron microscopy (SEM), electron back-scatter diffraction (EBSD) and tensile testing. It was found that primary particles due to a close orientation to matrix could serve as the potent heterogeneous nucleation sites for α-Al during solidification and thus impose a remarkable grain refinement effect. Eutectic structure consisted of layer by layer of ‘Al{sub 3}Sc + α-Al + Al{sub 3}Sc + ⋯’ and cellular-dendritic substructure were simultaneously observed at the particles inside, indicating that these particles could be identified as the eutectics rather than individual Al{sub 3}Sc phase. A calculating method, based on EBSD results, was introduced for the spatial distribution of these particles in matrix. The results showed that these eutectic particles randomly distributed in matrix. In addition, the formation of primary eutectic particles significant improved the strength of the Al-Mg alloy in as-cast condition, which is ascribed to the structural evolution from coarse dendrites to prefect fine equiaxed grains. On the other hand, these large-sized particles due to the tendency to act as the microcrack sources could cause a harmful effect in the ductility of Al-Mg-Sc alloy. - Highlights: •Primary particles exhibit an ‘Al{sub 3}Sc + α-Al + Al{sub 3}Sc + ⋯’ multilayer feature with a cellular-dendritic mode of growth. •EBSD analyses the mechanism of grain refinement and the distribution of primary particles in α-Al matrix. •A computational method was presented to calculate the habit planes of primary particles.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Inhibition of Polyimide Photodegradation by Incorporation of Titanate Nanotubes into a Composite

The effect of UV light exposure on the properties of hexafluoroisopropylidene-diphthalic anhydride–oxydianiline (6FDA–ODA) polyimide (PI) and polyimide–titanate nanotube (TiNT/PI) composites has been studied using Raman spectroscopy, optical microscopy, nanoidentation and TEM. The degree of polymer photodegradation was estimated by measuring the change in affinity to a positively charged dye (methylene blue, MB). The mechanism of photoassisted transformations in polyimides usually involves scission of polymer chains accompanied by appearance of active radicals, which undergo further rapid transformations to more stable phenol, amine, and carboxylic functional groups. The accumulation of these groups can increase the degree of adsorption of charged dyes in the photodegraded polymer. It was found that neat PI showed a significantly increased capacity to adsorb MB after irradiation with UV, reaching a plateau after 1 h. In contrast, TiNT/PI composite demonstrated a much slower rise in concentration of adsorbed MB even after 4 h of UV exposure. Raman spectra indicated cleavage of C=O and C–F bonds in PI while only the C–F bond was damaged in TiNT/PI. Shorter cracks (≈ 40 µm long) appeared in TiNT/PI composites whereas macro cracks (> 100 µm) were visible in neat PI after 3 h of UV exposure. Brittleness was studied by comparing plasticity index which varied from 0 to 1 (0 corresponding to the most brittle material and 1 the most ductile one). Plasticity index reduced by 51% and 2% for PI and TiNT/PI, respectively after 3 h UV irradiation, indicating that TiNT can protect underlying PI from further damage. The hardness of neat PI decreased whereas, for TiNT/PI, it increased under UV, suggesting crosslinking of broken polymer chains with nanotubes. Graphical Abstract: Photodegradation of a titanate nanotubes/polyimide composite can lead to cross-linking of broken polymer chains by nanostructured material, resulting in increased hardness. .

36 MATERIALS SCIENCE↗

DOE OSTI2015

Friction stir welding joint of dissimilar materials between AZ31B magnesium and 6061 aluminum alloys: Microstructure studies and mechanical characterizations

Friction stir welding is an efficient manufacturing method for joining dissimilar alloys, which can dramatically reduce grain sizes and offer high mechanical joint efficiency. Lap FSW joints between dissimilar AZ31B and Al 6061 alloy sheets were made at various tool rotation and travel speeds. Rotation and travel speeds varied between 560–1400 r/min and 16–40 mm/min respectively, where the ratio between these parameters was such that nearly constant pitch distances were applied during welding. X-ray diffraction pattern (XRD), optical microscopy images (OM), electron probe microanalysis (EPMA) and scanning electron microscopy equipped with an energy-dispersive X-ray spectroscopy (SEM-EDS) were used to investigate the microstructures of the joints welded. Intermetallic phases including Al{sub 12}Mg{sub 17} (γ) and Al{sub 3}Mg{sub 2} (β) were detected in the weld zone (WZ). For different tool rotation speeds, the morphology of the microstructure in the stir zone changed significantly with travel speed. Lap shear tensile test results indicated that by simultaneously increasing the tool rotation and travel speeds to 1400 r/min and 40 mm/min, the joint tensile strength and ductility reached a maximum. Microhardness measurements and tensile stress–strain curves indicated that mechanical properties were affected by FSW parameters and mainly depended on the formation of intermetallic compounds in the weld zone. In addition, a debonding failure mode in the Al/Mg dissimilar weld nugget was investigated by SEM and surface fracture studies indicated that the presence of intermetallic compounds in the weld zone controlled the failure mode. XRD analysis of the fracture surface indicated the presence of brittle intermetallic compounds including Al{sub 12}Mg{sub 17} (γ) and Al{sub 3}Mg{sub 2} (β). - Highlights: • Dissimilar Al/Mg joint was obtained by lap friction stir welding technique. • Effect of rotation and travel speeds on the formation of intermetallic compounds • Microstructure and chemical studies including metallography, XRD, SEM-EDS, and EPMA • Mechanical property tests such as stress–strain curves, failure load and hardness • IMCs as Al{sub 3}Mg{sub 2} and Al{sub 12}Mg{sub 17} were identified in weld nugget and at Al/Mg interface.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Prospects for sub-nanometer scale imaging of optical phenomena using electron microscopy

Imaging of optical phenomena at the sub-nanometer scale can offer fundamental insights into the electronic or vibrational states in atomic-scale defects, molecules, and nanoparticles, which are important in quantum information, heterogeneous catalysis, optoelectronics, and structural biology. Several techniques have surpassed the traditional Abbe diffraction limit and attained spatial resolutions down to a few nanometers, but sub-nanometer scale optics has remained elusive. Here, we propose an approach that combines spectrally specific photoabsorption with sub-nanometer scale resolution transmission electron microscopy (TEM) of photoexcited electrons. We first estimate the signal level and conditions required for imaging nanoscale optical phenomena in core-shell quantum dots (QDs) like CdS/CdTe. Furthermore, we show the possibility of imaging photoexcited states of atomic-scale defects in a monolayer hexagonal boron nitride (h-BN) using ab initio and high resolution (HR)TEM simulations. The ability to directly visualize photoexcited states at the sub-nanometer scale opens opportunities to study properties of individual quantum dots and atomic defects.

74 ATOMIC AND MOLECULAR PHYSICS↗

DOE OSTI2012

Microstructural evolution during solution treatment of Co-Cr-Mo-C biocompatible alloys

Three different Co-Cr-Mo-C alloys conforming to ASTM F75 standard were poured in an industrial environment and subjected to a conventional solution treatment at 1225 Degree-Sign C for several time intervals. The microstructural changes and transformations were studied in each case in order to evaluate the way in which treatment time influences the secondary phase fraction and clarify the microstructural changes that could occur. To assess how treatment time affects microstructure, optical microscopy and image analyzer software, scanning electron microscopy and energy dispersion spectrometry analysis were employed. The main phases detected in the as-cast state were: {sigma}-phase, M{sub 6}C, and M{sub 23}C{sub 6} carbides. The latter presented two different morphologies, blocky type and lamellar type. Despite being considered the most detrimental feature to mechanical properties, {sigma}-phase and lamellar carbides dissolution took place in the early stages of solution treatment. M{sub 23}C{sub 6} carbides featured two different behaviors. In the alloy obtained by melting an appropriate quantity of alloyed commercial materials, a decrease in size, spheroidization and transformation into M{sub 6}C carbides were simultaneously observed. In the commercial ASTM F75 alloy, in turn, despite being the same phase, only a marked decrease in precipitates size was noticed. These different behaviors could be ascribed to the initial presence of other phases in the alloy obtained from alloyed materials, such as {sigma}-phase and 'pearlitic' carbides, or to the initial precipitate size which was much larger in the first than in the commercial ASTM F75 alloy studied. M{sub 6}C carbides dissolved directly in the matrix as they could not be detected in samples solution-treated for 15 min. - Highlights: Black-Right-Pointing-Pointer Three different Co-Cr-Mo alloys were poured under an industrial environment. Black-Right-Pointing-Pointer Transformation of existing phases followed during conventional solution treatment. Black-Right-Pointing-Pointer In as-cast/treated samples, phases were identified by color metallography, SEM and EDS. Black-Right-Pointing-Pointer M{sub 23}C{sub 6} {yields} M{sub 6}C transformation was corroborated by SEM and EDS analysis. Black-Right-Pointing-Pointer Carbide spheroidization was also detected prior a noticeably carbide size decreasing.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Ca Addition Effects on the Microstructure, Tensile and Corrosion Properties of Mg Matrix Alloy Containing 8 wt.% Mg{sub 2}Si

The microstructure, tensile properties and corrosion behavior of the Mg-8 wt.% Mg{sub 2}Si-x%Ca alloy have been studied by the use of optical microscopy, scanning electron microscopy equipped with energy-dispersive spectroscopy, x-ray diffraction, standard tensile testing, polarization test and electrochemical impedance spectroscopy (EIS) measurements. Microstructural studies indicated that Ca modifies both primary and eutectic Mg{sub 2}Si phase. It was found that the average size of primary Mg{sub 2}Si particles is about 60 μm, which is dropped by about 82% in the alloy containing 0.05 wt.% Ca. By the addition of different Ca contents, Ca-rich intermetallics (i.e., CaSi{sub 2} and CaMgSi) were formed. The modification mechanism of adding Ca during solidification was found to be due to the strong effect of CaMgSi phase as a heterogonous nucleation site, apart from CaSi{sub 2} which was reported before, for Mg{sub 2}Si intermetallics. Tensile testing results ascertained that Ca addition enhances both ultimate tensile strength (UTS) and elongation values. The optimum amount of Ca was found to be 0.1 wt.%, which improved UTS and elongation values from about 130 MPa and 2% to 165 MPa and 5.5%, whereas more Ca addition (i.e., 3 wt.%) reduced the tensile properties of the alloy to about 105 MPa and 1.8%, which can be due to the formation of CaMgSi intermetallics with deteriorating needle-like morphology. Polarization and EIS tests also showed that the Mg-3%Si-0.5%Ca alloy pronounces as the best anti-corrosion alloy. Nevertheless, further added Ca (up to 3 wt.%) deteriorated the corrosion resistance due to predominance of worse galvanic coupling effect stemmed from the presence of stronger CaMgSi cathode in comparison with Mg{sub 2}Si. With higher Ca additions, an adverse effect was seen on corrosion resistance of the Mg-3%Si alloy, as a result of forming a weak film on the alloy specimen surface.

36 MATERIALS SCIENCE↗

DOE OSTI2011

Stainless steel corrosion by molten nitrates : analysis and lessons learned.

A secondary containment vessel, made of stainless 316, failed due to severe nitrate salt corrosion. Corrosion was in the form of pitting was observed during high temperature, chemical stability experiments. Optical microscopy, scanning electron microscopy and energy dispersive spectroscopy were all used to diagnose the cause of the failure. Failure was caused by potassium oxide that crept into the gap between the primary vessel (alumina) and the stainless steel vessel. Molten nitrate solar salt (89% KNO{sub 3}, 11% NaNO{sub 3} by weight) was used during chemical stability experiments, with an oxygen cover gas, at a salt temperature of 350-700 C. Nitrate salt was primarily contained in an alumina vessel; however salt crept into the gap between the alumina and 316 stainless steel. Corrosion occurred over a period of approximately 2000 hours, with the end result of full wall penetration through the stainless steel vessel; see Figures 1 and 2 for images of the corrosion damage to the vessel. Wall thickness was 0.0625 inches, which, based on previous data, should have been adequate to avoid corrosion-induced failure while in direct contact with salt temperature at 677 C (0.081-inch/year). Salt temperatures exceeding 650 C lasted for approximately 14 days. However, previous corrosion data was performed with air as the cover gas. High temperature combined with an oxygen cover gas obviously drove corrosion rates to a much higher value. Corrosion resulted in the form of uniform pitting. Based on SEM and EDS data, pits contained primarily potassium oxide and potassium chromate, reinforcing the link between oxides and severe corrosion. In addition to the pitting corrosion, a large blister formed on the side wall, which was mainly composed of potassium, chromium and oxygen. All data indicated that corrosion initiated internally and moved outward. There was no evidence of intergranular corrosion nor were there any indication of fast pathways along grain boundaries. Much of the pitting occurred near welds; however this was the hottest region in the chamber. Pitting was observed up to two inches above the weld, indicating independence from weld effects.

36 MATERIALS SCIENCE↗

DOE OSTI2014

Elemental segregation and subsequent precipitation during solidification of continuous cast Nb–V–Ti high-strength low-alloy steels

In this study, elemental segregation during solidification and subsequent precipitation behaviour in a continuous cast Nb–V–Ti high-strength low-alloy steel was investigated by optical microscopy, scanning electron microscopy with energy dispersive X-ray spectroscopy and thermodynamic modelling. It is known that for steels with low carbon contents the pearlite that forms on slow cooling does so where the interdendritic liquid was present prior to final solidification. The alloying elements of Nb, Ti, Mn and V segregate into the interdendritic liquid during solidification, while Al preferentially segregates into the solidifying solid phase. The composition analysis on the slab samples verified the predicted element segregation behaviour, with a smaller difference in the concentrations of Mn and V in the pearlite and dendritic ferrite regions being observed compared to the Nb levels. Small (30–100 nm) spherical or irregular shaped Nb-rich precipitates (Nb(C, N) and (Nb, V)(C, N)) were mainly found in the pearlite regions, while angular Al-rich (60–300 nm) precipitates were found in the dendritic ferrite regions, in the form of AlN and complex AlN–V(C, N) precipitates. Small isolated ferrite regions surrounded by pearlite were observed in the microstructure and has two origins: one type is dendritic ferrite that appears as an isolated island due to a sectioning effect when observing the two-dimensional microstructure; the other is a ferrite idiomorph that forms in the interdendritic region due to the low carbon content of the steel. Accordingly, in these isolated ferrite islands two different precipitation behaviours are found; predominantly Al-rich particles in the dendritic regions or predominantly Nb-rich precipitates in the interdendritic ferrite idiomorphs. No Al-rich precipitates were observed in the interdendritic regions (pearlite or isolated ferrite idiomorphs) despite the Thermo-Calc predictions indicating a higher volume fraction of AlN in these regions compared to the dendritic regions. This is believed to be due to back diffusion of nitrogen after solidification reducing the available nitrogen, which reacts with the high Nb levels present. - Highlights: • Nb-rich precipitates (Nb(C, N) and (Nb, V)(C, N)) were mainly found in pearlite. • Angular Al-rich precipitates (AlN and AlN–V(C, N)) were found in dendritic ferrite. • Precipitation behaviour in isolated ferrite islands within pearlite was revealed. • Segregation of substitutional elements during solidification is retained. • Back diffusion of interstitial elements (C, N) occurred.

36 MATERIALS SCIENCE↗

DOE OSTI2012

0.22 THz wideband sheet electron beam traveling wave tube amplifier: Cold test measurements and beam wave interaction analysis

In this paper, we describe micro-fabrication, RF measurements, and particle-in-cell (PIC) simulation modeling analysis of the 0.22 THz double-vane half period staggered traveling wave tube amplifier (TWTA) circuit. The TWTA slow wave structure comprised of two sections separated by two sever ports loaded by loss material, with integrated broadband input/output couplers. The micro-metallic structures were fabricated using nano-CNC milling and diffusion bonded in a three layer process. The 3D optical microscopy and SEM analysis showed that the fabrication error was within 2-3 {mu}m and surface roughness was measured within 30-50 nm. The RF measurements were conducted with an Agilent PNA-X network analyzer employing WR5.1 T/R modules with a frequency range of 178-228 GHz. The in-band insertion loss (S{sub 21}) for both the short section and long section (separated by a sever) was measured as {approx}-5 dB while the return loss was generally around {approx}-15 dB or better. The measurements matched well with the S-matrix simulation analysis that predicted a 3 dB bandwidth of {approx}45 GHz with an operating frequency at 220 GHz. However, the measured S{sub 21} was {approx}3 dB less than the design values, and is attributed to surface roughness and alignment issues. The confirmation measurements were conducted over the full frequency band up to 270 GHz employing a backward wave oscillator (BWO) scalar network analyzer setup employing a BWO in the frequency range 190 GHz-270 GHz. PIC simulations were conducted for the realistic TWT output power performance analysis with incorporation of corner radius of 127 {mu}m, which is inevitably induced by nano-machining. Furthermore, the S{sub 21} value in both sections of the TWT structure was reduced to correspond to the measurements by using a degraded conductivity of 10% International Annealed Copper Standard. At 220 GHz, for an elliptic sheet electron beam of 20 kV and 0.25 A, the average output power of the tube was predicted to be reduced from 90 W (for ideal conductivity/design S-parameters) to 70 W (for the measured S-parameters/inferred conductivity) for an average input power of 50 mW. The gain of the tube remains reasonable: {approx}31.4 dB with an electronic efficiency of {approx}1.4%. The same analysis was also conducted for several frequencies between 190 GHz-260 GHz. This detailed realistic PIC analysis demonstrated that this nano-machined TWT circuit has slightly reduced S-parameters and output power from design, but within an acceptable range and still have promising output power, gain, and band width as required. Thus, we expect to meet the specifications of 1000 W-GHz for the darpa program goals.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2012

Fe-24 wt.%Cr-4.1 wt.%C hardfacing alloy: Microstructure and carbide refinement mechanisms with ceria additive

The microstructure and carbide refinement mechanisms of Fe-24 wt.%Cr-4.1 wt.%C hardfacing alloys with 0 wt.%, 0.5 wt.%, 1.0 wt.%, 2 wt.%, and 4 wt.% ceria additives have been systematically investigated in this work. Optical microscopy, field emission scanning electron microscopy with energy dispersive spectrometer, and X-ray diffraction were collectively used to study the microstructure, the phase components, and the chemical formation of inclusion formed in the welding process. Wear-resistance of the alloys was comparatively studied using an abrasive wear testing machine. The structure analysis results show that the Fe-Cr-C hardfacing alloy mainly consists of martensite, retained austenite, MC carbide and M{sub 7}C{sub 3} carbide. With increasing ceria additive contents, the average size of the primary M{sub 7}C{sub 3} carbide decreases and reaches a most refined state in the alloy with 2 wt.% ceria additives. Comparative wear tests data shows that the wear resistance of the hardfacing alloys with ceria additives is better than that without ceria additive. In a good agreement with the carbide refinement results, the wear resistance of the alloy reaches an optimum level in the sample with 2 wt.% ceria additive. The main RE inclusion type identified with in-situ XRD analysis is RE inclusion Ce{sub 2}O{sub 2}S. Thermodynamics calculation confirms that this type of RE inclusion could precipitate prior to M{sub 7}C{sub 3} carbides, and act as a heterogeneous nucleus for M{sub 7}C{sub 3} in the welding process, which effectively provides a mechanism for significant refinement of the M{sub 7}C{sub 3} carbide and improves its wear resistance. - Graphical Abstract: Rare Earth inclusion (Ce{sub 2}O{sub 2}S) distributes in the primary M{sub 7}C{sub 3} carbide. Moreover, Ce{sub 2}O{sub 2}S, which acts as heterogeneous nuclei of the primary M{sub 7}C{sub 3} carbide, is medium effective. Therefore, the primary M{sub 7}C{sub 3} carbide has been refined. Highlights: Black-Right-Pointing-Pointer Micro-hardness of primary M{sub 7}C{sub 3} carbide in Fe-Cr-C hardfacing alloy is 1594 HV. Black-Right-Pointing-Pointer RE inclusion Ce{sub 2}O{sub 2}S can be observed in the primary M{sub 7}C{sub 3} carbide. Black-Right-Pointing-Pointer Ce{sub 2}O{sub 2}S as heterogeneous nuclei of the Cr{sub 7}C{sub 3} is medium effective. Black-Right-Pointing-Pointer Primary carbide is most refined with 2 wt.% ceria additive.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Free-space confocal magneto-optical spectroscopies at milliKelvin temperatures

We describe the operation of a free-space confocal optical microscope operated in a dilution refrigerator. The microscope is installed on a cold insertable probe to enable fast sample exchange while the refrigerator is held at low temperatures. A vector magnet provides a 6 T field normal to the sample and 1 T fields at arbitrary angles. A variety of optical microscopies and spectroscopies, including photoluminescence, Raman, magneto-optical Kerr effect, and spin relaxometry measurements are described, and some of the challenges associated with performing these measurements at milliKelvin temperatures are explored.

Lawrie, B. J.↗

DOE OSTI2021

Free-space confocal magneto-optical spectroscopies at milliKelvin temperatures

Lawrie, Benjamin↗