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DOE OSTI2022

Effect of various post-extrusion tempering on performance of AA2024 tubes fabricated by shear assisted processing and extrusion

In this report aluminum alloy 2024 (AA2024) tubes were extruded using the shear assisted processing and extrusion (ShAPE) method. As a ubiquitous aerospace alloy, AA2024 has reached a high degree of maturity with respect to manufacturing processes, alloy chemistry and heat treatment to maximize material strength. Therefore, over the eight decades since the introduction of this alloy, the mechanical properties have plateaued, and the extrusion speed has reached a 3.5 m/min ceiling using conventional extrusion. The ShAPE technique enabled an extrusion speed of AA2024 up to 7.4 m/min at 480 °C which is surpassing the extrudability chart of this alloy. Variation of the standard T3510 and T8510 post extrusion heat treatments were applied to improve the mechanical performance of the ShAPE extruded AA2024 tube. The ultimate tensile strength and yield strength of AA2024-T8510 ShAPE extruded tube are 522.0 ± 3.3 MPa and 510.7 ± 3.3 MPa, which are respectively 18% and 32% higher than ASM-typical and ASTM minimum values. The elongation at break of ShAPE extruded AA2024-T8510 tubes is two times higher than the ASM-typical and ASTM-minimum values. This improved ductility is attributed to the refinement of grain size and secondary phases as well as due to the uniform dispersion of sub-micron strengthening precipitates formed during the ShAPE process.

42 ENGINEERING↗

DOE OSTI2020

First-principles study on the mechanical and thermodynamic properties of MoNbTaTiW

Refractory high-entropy alloys (RHEAs) are emerging as new materials for high temperature structural applications because of their stable mechanical and thermal properties at temperatures higher than 2273 K. In this study, the mechanical properties of MoNbTaTiW REDEA are examined by applying calculations based on first-principles density functional theory (DFT) and using a large unit cell with 100 randomized atoms. The phase calculation of MoNbTaTiW with CALPHAD method shows the existence of a stable body-centered cubic structure at a high temperature and a hexagonal closely packed phase at a low temperature. The predicted phase, shear modulus, Young’s modulus, Poisson’s ratio, and hardness values are consistent with available experimental results. The linear thermal expansion coefficient, vibrational entropy, and vibrational heat capacity of MoNbTaTiW RHEA are investigated in accordance with Debye-Grüneisen theory. These results may provide a basis for future research related to the application of RHEAs.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Multilevel and multifidelity uncertainty quantification for cardiovascular hemodynamics

Standard approaches for uncertainty quantification in cardiovascular modeling pose challenges due to the large number of uncertain inputs and the significant computational cost of realistic three-dimensional simulations. Here, we propose an efficient uncertainty quantification framework utilizing a multilevel multifidelity Monte Carlo (MLMF) estimator to improve the accuracy of hemodynamic quantities of interest while maintaining reasonable computational cost. This is achieved by leveraging three cardiovascular model fidelities, each with varying spatial resolution to rigorously quantify the variability in hemodynamic outputs. We employ two low-fidelity models (zero- and one-dimensional) to construct several different estimators. Our goal is to investigate and compare the efficiency of estimators built from combinations of these two low-fidelity model alternatives and our high-fidelity three-dimensional models. We demonstrate this framework on healthy and diseased models of aortic and coronary anatomy, including uncertainties in material property and boundary condition parameters. Our goal is to demonstrate that for this application it is possible to accelerate the convergence of the estimators by utilizing a MLMF paradigm. Therefore, we compare our approach to single fidelity Monte Carlo estimators and to a multilevel Monte Carlo approach based only on three-dimensional simulations, but leveraging multiple spatial resolutions. We demonstrate significant, on the order of 10 to 100 times, reduction in total computational cost with the MLMF estimators. We also examine the differing properties of the MLMF estimators in healthy versus diseased models, as well as global versus local quantities of interest. As expected, global quantities such as outlet pressure and flow show larger reductions than local quantities, such as those relating to wall shear stress, as the latter rely more heavily on the highest fidelity model evaluations. Similarly, healthy models show larger reductions than diseased models. In all cases, our workflow coupling Dakota’s MLMF estimators with the SimVascular cardiovascular modeling framework makes uncertainty quantification feasible for constrained computational budgets.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2025

Fiber orientation and porosity in large-format extrusion process: The role of processing parameters

Controlling fiber orientation and porosity in short-fiber thermoplastic composites is important for enhancing mechanical, electrical and thermal properties in large-format additive manufacturing. This study employs a factorial design of experiments (DoE) to assess the effects of nozzle diameter (5.08 mm–10.16 mm), temperature (230–250 °C), and extruder screw speed (150–280 rpm) on flow rate, shear rate, porosity, fiber orientation, fiber length and tensile strength in 20 % carbon fiber-filled acrylonitrile butadiene styrene. ANOVA results show that screw speed significantly impacts flow rate, while nozzle diameter and temperature have lesser effects. Shear rate increases with smaller nozzles and higher speeds. Porosity decreases from 5.58 % with a 10.16 mm nozzle to 3.11 % with a 5.08 mm nozzle at 150 rpm due to increased shear rates, which induce shear thinning, reducing viscosity and facilitating gas escape. Larger nozzles (10.16 mm) produce larger, more heterogeneous pores, while smaller nozzles (5.08 mm) yield smaller, uniform pores. Beads produced with the 5.08 mm nozzle exhibit longer fiber lengths due to reduced residence time, lower shear stress, and better alignment. Fiber orientation improves with smaller nozzles due to higher shear rates but decreases with higher screw speeds (280 rpm) due to shorter residence times. The highest fiber alignment (A xx ∼ 0.65) and low porosity (∼3%) were achieved with a 5.08 mm nozzle at 150 rpm, while equivalent additive manufacturing-compression molding samples exhibited better tensile strength (∼93 MPa) under these conditions. In conclusion, these findings emphasize the importance of optimizing processing parameters to enhance fiber alignment and reduce porosity for improved mechanical performance.

Design of experiments↗

DOE OSTI2021

Effects of Strain Rate and Temperature on the Mechanical Properties of Simulated Silica Ionogels

Ionogels are hybrid materials formed by impregnating the pore space of a solid matrix with a conducting ionic liquid. By combining the properties of both component materials, ionogels can act as self-supporting electrolytes in Li batteries. In this study, molecular dynamics simulations are used to investigate the dependence of mechanical properties of silica ionogels on solid fraction, temperature, and pore width. Comparisons are made with corresponding aerogels. We find that the solid matrix fraction increases the moduli and strength of the ionogel. This varies nonlinearly with temperature and strain rate, according to the contribution of the viscous ionic liquid to resisting deformation. Additionally, owing to the temperature and strain sensitivity of the ionic liquid viscosity, the mechanical properties approach a linear mixing law at high temperature and low strain rates. The median pore width of the solid matrix plays a complex role, with its influence varying qualitatively with deformation mode. Narrower pores increase the relevant elastic modulus under shear and uniaxial compression but reduce the modulus obtained under uniaxial tension. Conversely, shear and tensile strength are increased by narrowing the pore width. All of these pore size effects become more pronounced as the silica fraction increases. Pore size effects, similar to the effects of temperature and strain rate, are linked to the ease of fluid redistribution within the pore space during deformation-induced changes in the geometry of the pores.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Characterization of hot-pressed von Alpen type NASICON ceramic electrolytes

The Na-ion conducting solid electrolyte NASICON is a promising solid state electrolyte (SSE) for use in Na based electrochemical systems. The effects of particle morphology and synthesis of von Alpen type NASICON via hot-pressing were investigated. Spray dried particles were shown to improve mechanical and electrochemical properties. X-ray diffraction, scanning electron microscopy, impulse excitation measurements, Vickers hardness, and impedance spectroscopy were used to correlate relationships between phase purity, microstructure, mechanical properties, and electrochemical properties. Scanning electron microscopy showed the presence of a glass phase as between 19.08% and 28.23% area percentage and a ZrO 2 phase between 0.46% and 3.51% area percentage in the hot-pressed samples. Impulse excitation showed elastic modulus varying from 83.65 to 97.65 GPa. The first values of Poisson's ratio and shear modulus of NASICON are reported as between 0.23 and 0.26 and 33.87 to 38.79 GPa, respectively. Vickers hardness and fracture toughness measurements showed Vickers hardness ranging from 4.30 to 4.68 GPa and fracture toughness ranging from 1.05 to 1.09 MPa m ½ . Impedance spectroscopy showed grain conductivities ranging from 1.023 to 1.287 mS/cm, with grain boundary resistance percentages between 73.22 and 47.5%. Total conductivities ranged from 0.292 to 0.596 mS/cm, with 0.596 mS/cm being achieved at room temperature for the spray dried powders with lower grain boundary resistance percentages.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2026

In situ studies on heavy ion irradiation and partial oxidation induced stacking faults and nanograins in tungsten nanolaminates

Understanding the microstructural evolution of tungsten (W) under extreme irradiation environments is critical for its application as a plasma-facing material in future fusion reactors. Heavy ion irradiation study offers expedited damage accumulation and thus allows irradiation tolerance property prediction in a short period of time. In this study we explore in situ Kr ion irradiation of W nanolaminates at 800 °C and uncover a complex interplay of irradiation-induced transformations, including the emergence of stacking faults, nanograin formation, and generation of thickened grain boundaries defined as GB regions with the thickness of up to 15 nm. High-resolution transmission electron microscopy studies reveal the formation of extended planar faults and a metastable hexagonal close-packed (hcp) phase within the body-centered cubic (bcc) matrix. These structural transitions are facilitated by irradiation-induced shear. They are further stabilized by the presence of oxygen, which promotes stacking fault formation and vacancy trapping. Elevated temperatures enhance defect mobility, enabling dynamic recrystallization into ultrafine grains and the thickening of GBs due to defect absorption and impurity segregation. These findings unravel non-equilibrium phase transformation pathways in heavy ion irradiated W and highlight the critical role of impurity-mediated defect dynamics in governing its radiation tolerance properties.

Wazeer, Adil [Purdue University]↗

DOE OSTI2024

Large spatiotemporal variability in aerosol properties over central Argentina during the CACTI field campaign

Abstract. Few field campaigns with extensive aerosol measurements have been conducted over continental areas in the Southern Hemisphere. To address this data gap and better understand the interactions of convective clouds and the surrounding environment, extensive in situ and remote sensing measurements were collected during the Cloud, Aerosol, and Complex Terrain Interactions (CACTI) field campaign conducted between October 2018 and April 2019 over the Sierras de Córdoba range of central Argentina. This study describes measurements of aerosol number, size, composition, mixing state, and cloud condensation nuclei (CCN) collected on the ground and from a research aircraft during 7 weeks of the campaign. Large spatial and multiday variations in aerosol number, size, composition, and CCN were observed due to transport from upwind sources controlled by mesoscale to synoptic-scale meteorological conditions. Large vertical wind shears, back trajectories, single-particle measurements, and chemical transport model predictions indicate that different types of emissions and source regions, including biogenic emissions and biomass burning from the Amazon and anthropogenic emissions from Chile and eastern Argentina, contribute to aerosols observed during CACTI. Repeated aircraft measurements near the boundary layer top reveal strong spatial and temporal variations in CCN and demonstrate that understanding the complex co-variability of aerosol properties and clouds is critical to quantify the impact of aerosol–cloud interactions. In addition to quantifying aerosol properties in this data-sparse region, these measurements will be valuable to evaluate predictions over the midlatitudes of South America and improve parameterized aerosol processes in local, regional, and global models.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

Convective and Turbulent Motions in Nonprecipitating Cu. Part III: Characteristics of Turbulence Motions

Velocity field in a nonprecipitating Cu under BOMEX conditions, simulated by SAM with 10-m resolution and spectral bin microphysics is separated into the convective part and the turbulent part, using a wavelet filtering. In Part II of the study properties of convective motions of this Cu were investigated. Here in Part III of the study, the parameters of cloud turbulence are calculated in the cloud updraft zone at different stages of cloud development. The main points of this study are (i) application of a fine-scale LES model of a single convective cloud allowed a direct estimation of turbulence parameters using the resolved flow in the cloud and (ii) the separation of the resolved flow into the turbulence flow and the nonturbulence flow allowed us to estimate different turbulent parameters with sufficient statistical accuracy. We calculated height and time dependences of the main turbulent parameters such as turbulence kinetic energy (TKE), spectra of TKE, dissipation rate, and the turbulent coefficient. It was found that the main source of turbulence in the cloud is buoyancy whose contribution is described by the buoyancy production term (BPT). The shear production term (SPT) increases with height and reaches its maximum near cloud top, and so does BPT. In agreement with the behavior of BPT and SPT, turbulence in the lower cloud part (below the inversion level) is weak and hardly affects the processes of mixing and entrainment. The fact that BPT is larger than SPT determines many properties of cloud turbulence. For instance, the turbulence is nonisotropic, so the vertical component of TKE is substantially larger than the horizontal components. Another consequence of the fact that BPT is larger than STP manifests itself in the finding that the turbulence spectrum largely obeys the -11/5 Bolgiano–Obukhov scaling. The classical Kolmogorov -5/3 scaling dominates for the low part of a cloud largely at the dissolving stage of cloud evolution. Using the spectra obtained we evaluated an “effective” dissipation rate which increases with height from nearly zero at cloud base up to 20 cm 2 s -3 near cloud top. The coefficient of turbulent diffusion was found to increase with height and ranged from 5 m 2 s -1 near cloud base to 25 m 2 s -1 near cloud top. In conclusion, the possible role of turbulence in the process of lateral entrainment and mixing is discussed.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

Linear analysis of the Kelvin–Helmholtz instability in relativistic magnetized symmetric flows

ABSTRACT We study the linear stability of a planar interface separating two fluids in relative motion, focusing on the symmetric configuration where the two fluids have the same properties (density, temperature, magnetic field strength, and direction). We consider the most general case with arbitrary sound speed cs, Alfvén speed vA, and magnetic field orientation. For the instability associated with the fast mode, we find that the lower bound of unstable shear velocities is set by the requirement that the projection of the velocity on to the fluid-frame wavevector is larger than the projection of the Alfvén speed on to the same direction, i.e. shear should overcome the effect of magnetic tension. In the frame where the two fluids move in opposite directions with equal speed v, the upper bound of unstable velocities corresponds to an effective relativistic Mach number $M_{\rm re}\equiv v/v_{\rm {f}\perp }\sqrt{(1-v_{\rm {f}\perp }^2)/(1-v^2)} \cos \theta =\sqrt{2}$, where $v_{\rm {f}\perp }=[v_{\rm {A}}^2+c_{\rm s}^2(1-v_{\rm {A}}^2)]^{1/2}$ is the fast speed assuming a magnetic field perpendicular to the wavevector (here, all velocities are in units of the speed of light), and θ is the laboratory-frame angle between the flow velocity and the wavevector projection on to the shear interface. Our results have implications for shear flows in the magnetospheres of neutron stars and black holes – both for single objects and for merging binaries – where the Alfvén speed may approach the speed of light.

Astronomy & Astrophysics↗

DOE OSTI2025

Sound Speeds of Solids from Ultrasonic Pulse Receiver Measurements

A common method of determining elastic material properties is utilizing an ultrasonic pulse receiver. This is a non-destructive test (NDT) causing no plastic deformation of the material. It requires a pulse generator, oscilloscope, and two transducers to measure the sound velocity of a material. Both longitudinal and shear sound velocities may be obtained by utilizing the appropriate transducer. Acoustic nondestructive testing methods are often used in manufacturing certification processes and for material defect detection in industry. These methods can also be utilized to directly measure the elastic moduli of a material without damaging the material. Overall, it is a low-cost experiment with minimal preparation, and is easy to use.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Mechanical and Thermal Properties for Uranium and U–6Nb Alloy from First-Principles Theory

Elasticity, lattice dynamics, and thermal expansion for uranium and U–6Nb alloy (elastic moduli) are calculated from density functional theory that is extended to include orbital polarization (DFT+OP). Introducing 12.5 at.% of niobium, substitutionally, in uranium softens all the cii elastic moduli, resulting in a significantly softer shear modulus (G). Combined with a nearly invariant bulk modulus (B), the quotient B/G increases dramatically for U–6Nb, suggesting a more ductile material. Lattice dynamics from a harmonic model coupled with a DFT+OP electronic structure is applied for α uranium, and the obtained phonon density of states compares well with inelastic neutron-scattering measurements. The Debye temperature associated with the lattice dynamics falls within the range of experimentally observed Debye temperatures and it also validates our quasi-harmonic (QH) phonon model. The QH Debye–Grüneisen phonon method is combined with a DFT+OP electronic structure and used to explore the anisotropic thermal expansion in α uranium. The anomalous negative thermal expansion (contraction) of the b lattice parameter of the α-phase orthorhombic cell is relatively well reproduced from a free-energy model consisting of QH-phonon and DFT+OP electronic structure contributions.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2021

Evaluating the grain-scale deformation behavior of a single-phase FCC high entropy alloy using synchrotron high energy diffraction microscopy

We report although the deformation behavior of high-entropy alloys (HEAs) has been extensively studied at the macroscale, many important properties have yet to be explored for these alloys at the microscale, thus hampering accurate prediction of damage and failure processes. Synchrotron high-energy diffraction microscopy (HEDM) and fast-Fourier transform-based crystal plasticity modeling was conducted to investigate the three-dimensional (3D) grain-resolved micromechanical response for approximately 1,900 constituent grains within a single-phase FCC HEA up to 1% applied strain. The evolution of grain-resolved elastic strains, lattice reorientations, and maximum resolved shear stresses (mRSS) were evaluated to quantify elastic, yield, and fully plastic behavior. Overall, the initial critical resolved shear stress (CRSS), determined via in situ HEDM and companion modeling, was found to be > 20% higher than estimated using the classical polycrystalline Taylor factor (M = 3.06). However, a descriptive parameter based on the average grain-resolved Taylor factor ($\overline{M}$) was found to show excellent agreement with plastic yielding behavior observed within HEDM datasets. Noticeable deviations in HEDM lattice reorientations compared to both EVP-FFT simulations and classical predictions for FCC polycrystals were discovered, highlighting the complexity in correlating local lattice reorientations, Taylor, and Schmid factors with plastic response for this material at the grain-scale. Therefore, it is anticipated that the overall trends and parameter identification of 3D grain-resolved properties in this study can serve as an important foundation for continued mesoscale investigation on both well-established and newly developed Cantor-like HEAs.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Acoustic velocities, elasticity, and pressure-induced elastic softening in compressed neodymium

For the first time, the acoustic velocities and elasticity of double hexagonal close-packed neodymium (Nd) were measured at high pressure using ultrasonic interferometry in conjunction with synchrotron X-ray techniques. Here, both the compressional and shear wave velocities increased with an increase in pressure of up to ~5.4 GPa before they exhibited almost constant values upon further compression. This pressure-induced elastic wave velocity softening can be attributed to the structural instability in dhcp-Nd. From the current sound velocities and density data, we obtained new bulk and shear moduli as well as their pressure dependence for polycrystalline dhcp-Nd, yielding $B_0$=33.2(9) GPa, $G_0$=14.1(5) GPa, $\partial$$B/$$\partial$$P$ = 3.6 (4) and $\partial$$=G/$$\partial$$P$ = 1.3 (2) while other elasticity-related/mechanical properties, including Young's modulus, Debye temperature, Poisson's ratio, and Grüneisen parameter, which are important parameters for the application of Nd in extreme environments, were also derived.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Chromium enhances the mechanical performance of 3d transition metal high entropy alloys

A comprehensive examination of the compositional effects on the deformation behavior of high entropy alloys (HEAs) was conducted through nanoindentation, indentation creep, and stress relaxation experiments at ambient temperature. The alloys investigated included NiCoFe, NiCoCr, NiCoCrFe, and NiCoCrFeMn, all of which underwent identical thermomechanical processing. From the experimental results, NiCoCr exhibited the highest maximum shear stress for dislocation nucleation (13 GPa) and nanoindentation hardness (3.8 GPa) among the alloys tested. It also showed the lowest stress sensitivity (0.02) and activation volume (3–4 b 3 ) under creep and stress relaxation conditions, indicative of its superior plastic flow properties. Density functional theory (DFT) calculations further revealed an uneven charge density and larger bonding-length variation in NiCoCr due to the presence of Cr, which increased lattice distortion, impeding dislocation movement. Furthermore, in this study, post-deformation microscopy using transmission electron microscopy (TEM) revealed a high density of stacking faults and twins in NiCoCr that effectively enhanced its creep strength. The results highlight the significance of specific elemental effects, particularly from Cr in this study, over configurational entropy effect (i.e., compositional complexity) in governing the deformation microstructure and mechanical properties of HEAs. Finally, these insights will be instrumental for the design and optimization of advanced alloys for load-bearing applications.

36 - MATERIALS SCIENCE↗

DOE OSTI2024

"Hall" transport of liquid crystal solitons in Couette flow

Topology establishes a unifying framework for a diverse range of scientific areas including particle physics, cosmology, and condensed matter physics. One of the most fascinating manifestations of topology in the context of condensed matter is the topological Hall effect, and its relative: the Skyrmion Hall effect. Skyrmions are stable vortex-like spin configurations in certain chiral magnets, and when subject to external electric currents can drift in the transverse direction to the current. These quasi-particles are characterised by a conserved topological charge which in the Skyrmion Hall effect plays the role of electric charges in the ordinary Hall effect. Recently, it has been shown that liquid crystals endowed with chiral properties serve as an ideal testbed for the fundamental investigation of topological solitons, including their two- and three-dimensional realisations. Here, we show experimentally and numerically that three-dimensional solitons aka "torons" exhibit a Hall-like effect when driven by shear flows: the torons are deflected in the direction perpendicular to the shear plane. The experimental results are rationalised in terms of the dynamic Ericksen-Leslie equations, which predict the emergence of the transverse component of the net mass flow, the magnitude of which scales as the 3rd power of the shear rate. The perturbation analysis highlights an interplay of the viscous and chiral elastic torques as the mechanism for the emergence of net transverse currents. Numerical simulations demonstrate, however, that torons are not merely dragged by the flow but move with their own transverse speed, much larger than the average flow velocity in the transverse direction. Our findings may enable responsive microfluidic applications relying on soft topological solitons.

FOS: Physical sciences↗

DOE OSTI2021

New Extrusion Method is Taking ShAPE

PNNL’s patented Shear Assisted Processing and Extrusion (ShAPE™) includes a novel extrusion machine, tooling, and associated processing techniques that delivers high-performance metal alloys for a wide range of market needs. ShAPE is a technique for manufacturing wire, bar, and tubular extrusions with unprecedented properties and manufacturing advantages compared to conventional extrusion. In a single step, ShAPE extrudes metal powder, flake, chip, and ingot directly into products with properties that cannot be achieved by conventional means. ShAPE delivers better products, because it uniquely mixes and deforms the metal feedstocks in their solid form without melting them, dramatically improving product properties and the energy efficiency of production.

Joshi, Vineet V.↗

DOE OSTI2020

Comparison of semi-doped PANI/DBSA complex achieved by thermal doping and roll-mill process: A new perspective for application

Conductive polymers have garnered extensive attention over the last few decades owing to their vast applications and relative ease of production. One such polymer is PANI; with versatile thermo-mechanical, chemical, and electrical properties, has been researched for varied applications in the field of electronics, electrodes and corrosion protection. In this study, we focus on an alternative route to process semi-doped PANI/DBSA complexes with special focus on material properties for improved processability. This study investigates the influence of two different material preparation techniques: roll-milling and thermal-doping, on the formability and processability of such polymer-complex systems. Results confirm similar doping levels achieved in both processes and shear-thinning behavior was only observed for roll-milled samples. These results underline the formability of roll-milled PANI/DBSA with thermosetting resins. It essentially explains the production route and offers a perspective for commercial manufacturing.

36 MATERIALS SCIENCE↗