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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 469 records · Page 26
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Direct ink writing of boron carbide monoliths

Direct ink writing – an extrusion-based additive manufacturing process – followed by pressureless sintering was investigated to produce boron carbide monoliths. The effects of ceramic powder loading and Pluronic binder concentration on the rheology of boron carbide pastes were studied and linked to both processing behaviour and final outcome in terms of sintered density and hardness. The effects of printing parameters, in particular orifice diameter and printing speed, were also investigated. Reducing the size of the extrusion nozzle from 584 μm to 406 μm led to significantly better shape retention, lower surface roughness, as well as higher density and hardness. A 203 μm printing orifice was also trialled but was unsuccessful due to faster drying kinetics that occurred with smaller ceramic struts resulting in rapid warping and nozzle clogging. Carbon-black – 8 wt% relative to B 4 C – acted as an effective sintering aid to increase both density and hardness. After optimisation of feedstock and printing parameters, few-layer samples (3–5 layers) had a density as high as ~ 97 % TD and a hardness of ~ 30 GPa. On the other hand, 18-layer specimens had a sintered density of ~ 87 % TD, despite a fully dense microstructure, due to the formation of a 3D array of inter-strut pores. Nevertheless, several issues that arose during manufacturing and post-processing were detrimental to the density and structural integrity of printed specimens; these issues were identified, discussed, and suggestions for future work are provided in this report.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Synthesis of high-entropy carbides from multi-metal polymer precursors

Three compositions of high-entropy carbides, (TiHfVNbTa)C, (TiZrHfNbTa)C and (TiZrNbTaW)C were synthesized via a modified Pechini process, in which citric acid served as both a cation chelating agent and a carbon source. Through pyrolysis and spark plasma sintering, single phase high-entropy carbides were formed from the homogeneous precursors at a relatively low temperature of 1800 °C. The dispersion of cations in the polymer precursor facilitated shorter diffusion distances in polymer-derived materials, and thus compositional homogeneity was significantly improved relative to materials produced by a solid-state method, as quantified by a defined coefficient of variation applied to energy-dispersive X-ray spectroscopy. Finally, a finer microstructure in polymer-derived materials results in improved fracture toughness with a K IC value of 4.29 MPa·m 1/2 achieved for (TiHfVNbTa)C.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Density functional theory calculations of the mixing enthalpy of ternary uranium carbide compounds

The high melting point of uranium-zirconium carbides (U,Zr)C makes them an ideal fuel for nuclear thermal propulsion (NTP) reactors. Gaps remain in the current understanding of the U-Zr-C system due to the difficulty of conducting thermodynamic experiments at NTP operation conditions. Density functional theory calculations using the Hubbard U model (DFT+U) were performed using orbital matrix occupation (OMC) to obtain the mixing enthalpy for UC and ZrC for (U,Zr)C ternary compounds. Similarly, DFT+U calculations were also carried out for the (U,Nb)C and (U,Ta)C systems. In conclusion, the DFT results are envisioned to be used in thermodynamic assessments of the uranium carbide systems based on the CALPHAD approach to supplement the lack of experimental data for the mixing thermodynamics.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2012

C-Cr segregation at grain boundary before the carbide nucleation in Alloy 690

The grain boundary segregation in Alloy 690 was investigated by atom probe tomography. B, C and Si segregated at the grain boundary. The high concentration regions for each segregation element form a set of straight arrays that are parallel to each other in the grain boundary plane. The concentration fluctuation has a periodicity of about 7 nm in the grain boundary plane. Before the Cr{sub 23}C{sub 6} nucleation at grain boundaries, the C-Cr co-segregate on one side of the grain boundaries while not the exact grain boundary core regions have been detected. The reasons why grain boundary carbides have coherent orientation relationship only with one side of nearby grain which grain boundary is located at high index crystal plane were discussed. - Highlights: Black-Right-Pointing-Pointer Grain boundary segregation in Alloy 690 was investigated by atom probe tomography. Black-Right-Pointing-Pointer B, C and Si segregate at the grain boundary. Black-Right-Pointing-Pointer Concentration of segregated atoms periodicity fluctuated in the grain boundary plane. Black-Right-Pointing-Pointer C and Cr co-segregate on one side of the grain boundary before carbide nucleation.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Characterization of complex carbide–silicide precipitates in a Ni–Cr–Mo–Fe–Si alloy modified by welding

Nickel based alloys of the type Hastelloy-N™ are ideal candidate materials for molten salt reactors, as well as for applications such as pressure vessels, due to their excellent resistance to creep, oxidation and corrosion. In this work, the authors have attempted to understand the effects of welding on the morphology, chemistry and crystal structure of the precipitates in the heat affected zone (HAZ) and the weld zone of a Ni–Cr–Mo–Fe–Si alloy similar to Hastelloy-N™ in composition, by using characterization techniques such as scanning and transmission electron microscopy. Two plates of a Ni–Cr–Mo–Fe–Si alloy GH-3535 were welded together using a TiG welding process without filler material to achieve a joint with a curved molten zone with dendritic structure. It is evident that the primary precipitates have melted in the HAZ and re-solidified in a eutectic-like morphology, with a chemistry and crystal structure only slightly different from the pre-existing precipitates, while the surrounding matrix grains remained unmelted, except for the zones immediately adjacent to the precipitates. In the molten zone, the primary precipitates were fully melted and dissolved in the matrix, and there was enrichment of Mo and Si in the dendrite boundaries after solidification, and re-precipitation of the complex carbides/silicides at some grain boundaries and triple points. The nature of the precipitates in the molten zone varied according to the local chemical composition. - Graphical abstract: Display Omitted - Highlights: • Ni-based alloy with Cr, Mo, Si, Fe and C was welded, examined with SEM, EBSD, and TEM. • Original Ni{sub 2}(Mo,Cr){sub 4}(Si,C) carbides changed from equiaxed to lamellar shape in HAZ. • Composition and crystal structure remained almost unchanged in HAZ. • Original carbides changed to lamellar Ni{sub 3}(Mo,Cr){sub 3}(Si,C) in some cases in weld metal. • Precipitates were mostly incoherent, but semi-coherent in some cases in weld metal.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Strain-induced ordered structure of titanium carbide during depositing diamond on Ti alloy substrate

During the deposition of diamond films on Ti alloy substrates, titanium carbide is a common precipitated phase, preferentially formed at the interfacial region. However, in this case, the precipitation of an ordered structure of titanium carbide has not been reported. In our work, a long periodic ordered structure of TiC has been observed at the deposited diamond film/Ti alloy interface by high resolution transmission electron microscopy (HRTEM). The long periodic ordered structure is identified as 6H-type. The formation mechanism is revealed by comparative studies on the different structures of TiC precipitated under different diamond deposition conditions in terms of deposition time, atmosphere and temperature. A large number of carbon vacancies in the interfacial precipitated TiC phase are verified through electron energy loss spectroscopy (EELS) quantification analysis. However, an ordered arrangement of these carbon vacancies occurs only when the interfacial stress is large enough to induce the precipitation of 6H-type TiC. The supplementary analysis by X-ray diffraction (XRD) further confirms that additional diffraction peaks presented in the XRD patterns are corresponding to the precipitation of 6H-type TiC. - Highlights: •Different structures of TiC are observed during deposited diamond on Ti alloy. •One is common NaCl structure, the other is periodic structure. •The periodic structure is identified as 6H-type by HRTEM. •Carbon vacancies are verified to always exist in the TiC phase. •The precipitation of 6H-type TiC is mainly affected by interfacial stress.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Grinding-induced metallurgical alterations in the binder phase of WC-Co cemented carbides

The metallic binder phase dictates the toughening behavior of WC-Co cemented carbides (hardmetals), even though it occupies a relative small fraction of the composite. Studies on deformation and phase transformation of the binder constituent are scarce. Grinding represents a key manufacturing step in machining of hardmetal tools, and is well-recognized to induce surface integrity alterations. In this work, metallurgical alterations of the binder phase in ground WC-Co cemented carbides have been assessed by a combination of electron back scattered diffraction and transmission electron microscopy techniques. The Co-base binder experiences a martensitic phase transformation from fcc to hcp crystal structure, predominantly in the first 5 μm below the surface. The hcp fraction decreases gradually along a depth of 10 μm. Surface Co displays severe plastic deformation under the highest strain, resulting in formation of nanocrystalline grains in the first micrometer below the surface. Microstructural refinement within the binder phase is observed even at greater depth. Stacking faults were detected in most of the refined grains. The metallurgical alterations of the binder phase modify the local stress distribution during grinding, which affects the discerned subsurface microcracking. The resulting residual stress profile is the sum of multiple subsurface changes, such as phase transformation, severe plastic deformation and grain refinement, where it is discerned that the depth profile of the transformed hcp-Co fraction coincides with the grinding-induced residual stress profile.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Meso-scale microstructural agglomerate quantification in boron carbide using X-ray microcomputed tomography

Highlights: • First known quantification of agglomerate defect distributions comprising of carbonaceous and aluminum nitride phases B{sub 4}C. • In-depth statistical analyses of the size, orientation, and morphology of the defects. • The determination of directional dependence of the hot-pressing direction on the agglomerate distributions. - Abstract: Failure in brittle materials is governed, in part, by the specific microstructure of that material, with heterogeneous microstructures generally leading to reduced mechanical properties and performance. In ceramics used for armor, an increase in compressive strength can be an indicator of improved ballistic performance. In hot-pressed boron carbide (B{sub 4}C) ceramic plates, failure has been attributed to carbonaceous flakes observed on the fracture surfaces of failed specimens. However, this current work shows agglomerates, in addition to the carbonaceous flakes, are present in this boron carbide. The density and distribution of these agglomerates are believed to influence the ballistic performance. Therefore, it is of interest to improve the quantification of meso-scale microstructural agglomerates so that strategies can be developed to mitigate them. This work is focused on the microstructural characterization of dumbbell-shaped compression specimens that were machined from a single tile of pressure-aided densification (PAD) B{sub 4}C, using high-resolution micro-computed tomography (microCT). Large clusters of non-B{sub 4}C agglomerates, up to 125 μm in diameter, were observed in addition to the typical smaller carbonaceous flakes and aluminum-based phases. Agglomerate size distribution, orientation, morphology, and spacing were quantified both parallel and perpendicular to the pressing direction. This defect quantification provides valuable information for a better understanding of the material microstructure which is a critical step in improving armor materials for the future.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Achieving superior mechanical properties: Tailoring multicomponent microstructure in AISI 9254 spring steel through a two-stage Q&P process and nanoscale carbide integration

In the pursuit of lightweight, durable steel, we have successfully developed a multicomponent structure in AISI 9254 spring steel using a two-stage quenching and partitioning (Q&P) process. The primary objective of this process was to engineer an optimized microstructure consisting of nanobainite, martensite, and nano-carbides. Utilizing the insights gained from the results of advanced techniques such as X-ray diffraction (XRD), scanning electron microscopy (SEM), transmission electron microscopy (TEM), and atom probe tomography (APT) performed on the as-received AISI 9254 spring steel, we refined the quenching and partitioning (Q&P) path, leading to the successful establishment of a bainitic transformation for superior mechanical properties. Our tensile tests revealed a high yield strength (≈ 1600 ± 25 MPa) and ultimate tensile strength (≈ 1850 ± 50 MPa), along with considerable elongation (≈ 11.15 ± 0.25%). We also identified that pre-formed martensite lath defects and high silicon content play crucial roles during the Q&P process, preventing carbide coalescence and increasing strain-hardening capacity. Finally, this study demonstrates the potential of a Q&P process to generate high-strength, ductile steel for automotive and aerospace applications.

36 MATERIALS SCIENCE↗
DOE OSTI2011

Structural stability and mutual transformations of molybdenum carbide, nitride and phosphide

Graphical abstract: Both Mo{sub 2}C and Mo{sub 2}N can be transformed to MoP, whereas the reverse changes are inviable, which is used to develop a promising and practical pathway for preparing MoP nanoparticles. Highlights: {yields} Mo carbide, nitride and phosphide are prepared. {yields} The structural stability increases in the order of Mo{sub 2}N < Mo{sub 2}C < MoP. {yields} Both Mo{sub 2}C and Mo{sub 2}N can be transformed to MoP, whereas the reverse changes are inviable. {yields} This study develops a promising and practical pathway for preparing MoP nanoparticles. -- Abstract: The structural stability and transformations of Mo carbide, nitride and phosphide were investigated under various atmosphere conditions by X-ray diffraction (XRD). The results indicated that the order of structural stability of these Mo-based compounds was as follows: Mo{sub 2}N < Mo{sub 2}C < MoP. Both Mo{sub 2}C and Mo{sub 2}N can be transformed to MoP, whereas the reverse transformations did not occur. Noticeably, compared with those Mo sources containing oxygen, the use of Mo{sub 2}C/Mo{sub 2}N as Mo-source can produce finely dispersed MoP nanoparticles by the temperature-programmed reaction (TPR) method. The result was probably due to the fact that lower-levels H{sub 2}O generated during synthesis process can avoid strong hydrothermal sintering. The influence of formation energy had been considered and was found to relate to the structural stability and transformations of these Mo-based compounds.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Mechanochemical synthesis of tungsten carbide nano particles by using WO{sub 3}/Zn/C powder mixture

Graphical abstract: Display Omitted Highlights: ► Nano particles of WC are synthesized by mechanochemical process. ► Zn was used to reduce WO{sub 3}. ► By removing ZnO from the milling products with an acid leaching, WC will be the final products. ► XRD results showed that the reduction reactions were completed after 36 h. ► TEM and SEM images showed that the morphology of produced powder is nearly spherical like. -- Abstract: In this research we introduce a new, facile, and economical system for fabrication of tungsten carbide (WC) nano particle powder. In this system WO{sub 3}, Zn, and C have been ball-milled for several hours, which led to the synthesis of tungsten carbide nano particles. The synthesized WC can successfully be separated from the ball-milled product by subjecting the product powder to diluted HCl for removing ZnO and obtaining WC. X-ray diffraction (XRD) analysis indicates that the reduction of WO{sub 3} will be completed gradually by increasing milling time up to 36 h. Scanning electron microscope (SEM), and transmission electron microscope (TEM) images show that after 36 h of milling the particle size of the fabricated powder is nano metric (about 20 nm). Results have shown that this system can surmount some main problems occurred in previous similar WC synthesizing systems. For example carbothermic reduction reactions, which lead to the synthesis of W{sub 2}C instead of WC, would not be activated because in this system reactions take place gradually.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Growth of boron doped hydrogenated nanocrystalline cubic silicon carbide (3C-SiC) films by Hot Wire-CVD

Highlights: • Boron doped nc-3C-SiC films prepared by HW-CVD using SiH{sub 4}/CH{sub 4}/B{sub 2}H{sub 6}. • 3C-Si-C films have preferred orientation in (1 1 1) direction. • Introduction of boron into SiC matrix retard the crystallanity in the film structure. • Film large number of SiC nanocrystallites embedded in the a-Si matrix. • Band gap values, E{sub Tauc} and E{sub 04} (E{sub 04} > E{sub Tauc}) decreases with increase in B{sub 2}H{sub 6} flow rate. - Abstract: Boron doped nanocrystalline cubic silicon carbide (3C-SiC) films have been prepared by HW-CVD using silane (SiH{sub 4})/methane (CH{sub 4})/diborane (B{sub 2}H{sub 6}) gas mixture. The influence of boron doping on structural, optical, morphological and electrical properties have been investigated. The formation of 3C-SiC films have been confirmed by low angle XRD, Raman spectroscopy, X-ray photoelectron spectroscopy (XPS), Fourier transform infra-red (FTIR) spectroscopy and high resolution-transmission electron microscopy (HR-TEM) analysis whereas effective boron doping in nc-3C-SiC have been confirmed by conductivity, charge carrier activation energy, and Hall measurements. Raman spectroscopy and HR-TEM analysis revealed that introduction of boron into the SiC matrix retards the crystallanity in the film structure. The field emission scanning electron microscopy (FE-SEM) and non contact atomic force microscopy (NC-AFM) results signify that 3C-SiC film contain well resolved, large number of silicon carbide (SiC) nanocrystallites embedded in the a-Si matrix having rms surface roughness ∼1.64 nm. Hydrogen content in doped films are found smaller than that of un-doped films. Optical band gap values, E{sub Tauc} and E{sub 04} decreases with increase in B{sub 2}H{sub 6} flow rate.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Quantitative investigation into the influence of temperature on carbide and austenite evolution during partitioning of a quenched and partitioned steel

Here, the influence of partitioning temperature on microstructural evolution during quenching and partitioning was investigated in a 0.38C-1.54Mn-1.48Si wt.% steel using Mössbauer spectroscopy and transmission electron microscopy. η-carbide formation occurs in the martensite during the quenching, holding, and partitioning steps. More effective carbon partitioning from martensite to austenite was observed at 450 than 400°C, resulting in lower martensite carbon contents, less carbide formation, and greater retained austenite amounts for short partitioning times. Conversely, greater austenite decomposition occurs at 450°C for longer partitioning times. Lastly, cementite forms during austenite decomposition and in the martensite for longer partitioning times at 450°C.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Cobalt Metal–Cobalt Carbide Composite Microspheres for Water Reduction Electrocatalysis

Microspheres of cobalt metal–cobalt carbide (Co–Co x C, Co x C: Co 2 C and Co 3 C) composite with carbon shells were prepared via an OH – - and Cl – -assisted polyol method and explored for electrocatalytic activity and stability for the hydrogen evolution reaction (HER) in acidic media. From our transmission electron microscopy observations, the outermost surfaces of the as-prepared Co–Co x C composites were primarily covered with Co 2 C crystallites. Our best performing electrocatalyst exhibited superior HER activity with an overpotential of 78 mV to reach a current density of -10 mA·cm –2 , a Tafel slope of 87.8 mV·dec –1 , and 1 h of electrode durability. We show that this excellent HER performance is primarily due to the superior intrinsic activity of Co 2 C, as well as the high electrical conductivity resulting from the inclusion of cobalt metal and the presence of graphitic carbon shells in and on the composite, respectively. Using both computational and experimental approaches, we determine here that the carbon-rich cobalt carbide (Co 2 C) phase is more favorable for the HER than the carbon-poor phase (Co 3 C).

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

Ab Initio Predictions of Strong Interfaces in Transition-Metal Carbides and Nitrides for Superhard Nanocomposite Coating Applications

Conceiving strong interfaces represents an effective direction in the development of superhard nanocomposite materials for practical applications in protective coatings. Additionally, in the pursuit of engineering strong nanoscale interfaces between cubic rock-salt (B1) domains, we investigate using density functional theory (DFT) coherent interface models designed based on hexagonal (HX) NiAs and WC structures, as well as experiment. The DFT screening of a collection of transition-metal (M = Zr, Hf, Nb, Ta) carbides and nitrides indicates that the interface models provided by the HX polymorphs store little coherency strain and develop an energetic advantage as the valence-electron concentration increases. Finally, our result suggests that harnessing the polymorphism encountered in transition-metal (M = Zr, Hf, Nb, Ta) carbides and nitrides for interface design represents a promising strategy for advancing superhard nanomaterials.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Hydrogenation of CO 2 to methanol: Importance of metal–oxide and metal–carbide interfaces in the activation of CO 2

In this study, the high thermochemical stability of CO 2 makes it very difficult to achieve the catalytic conversion of the molecule into alcohols or other hydrocarbon compounds, which can be used as fuels or the starting point for the generation of fine chemicals. Pure metals and bimetallic systems used for the CO 2 → CH 3 OH conversion usually bind CO 2 too weakly and, thus, show low catalytic activity. Here, we discuss a series of recent studies that illustrate the advantages of metal–oxide and metal–carbide interfaces when aiming at the conversion of CO2 into methanol. CeO x /Cu(111), Cu/CeO x /TiO 2 (110), and Au/CeO x /TiO 2 (110) exhibit an activity for the CO 2 → CH 3 OH conversion that is 2–3 orders of magnitude higher than that of a benchmark Cu(111) catalyst. In the Cu–ceria and Au–ceria interfaces, the multifunctional combination of metal and oxide centers leads to complementary chemical properties that open active reaction pathways for methanol synthesis. Efficient catalysts are also generated after depositing Cu and Au on TiC(001). In these cases, strong metal–support interactions modify the electronic properties of the admetals and make them active for the binding of CO 2 and its subsequent transformation into CH 3 OH at the metal–carbide interfaces.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Multi-Scale Modeling for Plasma-Enhanced Ammonia Decomposition over Carbides and Nitrides

Ammonia is a carbon-free hydrogen carrier, but its decomposition typically requires high temperatures over costly Ru-based catalysts due to the large barrier for N≡N bond formation. We develop a multiscale framework combining density functional theory, zero-dimensional plasma kinetics, and microkinetic modeling to elucidate how non-thermal plasma (NTP) enables low-temperature NH 3 decomposition over Co-based carbides and nitrides, benchmarked against Ru and Co. Under thermal conditions, all catalysts are limited by N≡N bond formation, with Co 3 C(001) most active owing to its negatively charged surface, strong N* binding, and low activation barriers of N≡N bond formation. Plasma-induced vibrational excitation of NH 3 and its reactive radicals promotes a radical-driven •NH 2 –N* coupling pathway that dominates on Co 3 C(001) and Co 3 N(001), shifting the rate-limiting step to NH 3 (v1) dissociation, increasing turnover frequencies by up to 6 orders of magnitude, and reducing the temperature needed to reach a turnover frequency of 5 s –1 from >680 °C (Ru and Co under thermal condition) to 267 °C (Co 3 C) and 415 °C (Co 3 N). These results identify Co-based carbides and nitrides as promising plasma-active catalysts for energy-efficient hydrogen production from ammonia.

ammonia decomposition↗
DOE OSTI2026

Enhancing Acidic Oxygen Evolution Activity by Supporting Iridium Electrocatalysts on Tantalum Carbide

For a high-performance proton exchange membrane water electrolyzer (PEMWE), acidic oxygen evolution reaction (OER) electrocatalysts require highly dispersed iridium oxide (IrO x ) nanoparticles. Although carbon-based materials have been explored as promising supports for IrO x nanoparticles, their limited stability under harsh oxidative and acidic PEMWE conditions remains a significant challenge. Here, in this study, we report the synthesis and in situ characterization of active and durable IrOx electrocatalysts supported on electrochemically stable and electrically conducting tantalum carbide (TaC). When applied in a PEMWE, the IrO x /TaC electrocatalyst achieves a cell voltage of 1.71 V at 1.0 A cm –2 , outperforming the commercial IrO 2 catalyst (1.82 V at 1.0 A cm –2 ). Furthermore, the IrO x /TaC catalyst maintains a stable operation for 200 h at 0.5 A cm –2 with a low degradation rate of 36 μV h –1 . Density functional theory calculations further confirm that Ir–O–Ta bond formation at the IrO x /TaC interface reduces the overpotential of the OER compared to IrO 2 . This study underscores the pivotal role of supporting IrO x over stable and conducting metal carbides, providing guidance for the design of advanced acidic OER catalysts.

58 GEOSCIENCES↗