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At least 595 records · Page 33

Interfacial microstructure and mechanical properties of rotary inertia friction welded dissimilar 422 martensitic stainless steel to 4140 low alloy steel joints

In this work, dissimilar rotary inertia friction welds between 422 martensitic stainless steel and 4140 martensitic low-alloy steel were made to fabricate prototype heavy-duty diesel engine pistons. The influence of the inertia friction welding process and post weld heat treatment (PWHT) temperature on the interfacial microstructure evolutions and corresponding effects on mechanical properties of the 422/4140 welds were evaluated in detail. Carbon diffused from the 4140 side to the 422 side during PWHT at 650 °C for 1.5 h, causing the formation of a hard carbide-rich layer on the 422 side, and a softer but discontinuous C-depleted layer the 4140 side. PWHT at 700 °C for 1.5 h greatly accelerated C diffusion across the interface relative to 650 °C, resulting in a thicker hard carbide-rich layer and a relatively thick and continuous layer of coarse C-depleted grains (ferrite) on the 4140 side. In addition, the PWHT temperature greatly influenced the tensile properties and fracture behavior of the welds, with the 650 °C PWHT-ed samples failing predominately in a ductile manner in the 4140 heat affected zone during tensile testing. Conversely, the 700 °C PWHT specimens exhibited a strength reduction compared with the 650 °C PWHT specimens because of additional coarsening of the interfacial ferrite layer and softening of the base materials during PWHT, with brittle fracture between the hard and soft layers the predominate failure mechanism. Based on the findings, a reduced PWHT temperature and/or time, minimizing the hardness differential of the base metals, and pre-heating the 422 steel prior to welding are the potential pathways to achieve a more optimal balance between desirable tempering and stress relief of the weld microstructure and undesirable C migration across the weld interface, and to reduce the strength mismatch across the weld.

36 MATERIALS SCIENCE↗

Laser powder bed fusion of oxide dispersion-strengthened IN718 alloys: A complementary study on microstructure and mechanical properties

In this study, two new grades of oxide dispersion strengthened (ODS) Inconel 718 (IN718) alloys were designed by the thermochemical CALPHAD method and produced by laser powder bed fusion (LPBF) technique. Alloys designated as IN718-YF and IN718-YFH, that consist Y 2 O 3 –FeO and Y 2 O 3 –FeO–Hf, respectively, were fabricated with >99.9 % densification using optimized process parameters. CALPHAD calculations were highly consistent with experimental findings, highlighting the formation of Al-containing Y–Ti–O and Y–Hf–O nano-oxides in both alloy types. Texture analyzes revealed no significant texture development in as-built (AB) or heat-treated (HT) alloys. Heat treatment was applied at 1050 °C for 1 h to enhance nano-oxide density. Further, the nano-oxide number density remained similar in IN718-YF while it decreased in IN718-YFH alloy as a result of carbide formation after the heat treatment. Besides, formation of secondary γ' particles was observed in the IN718-YFH/HT alloy. Even though the yield strengths of IN718-YF and IN718-YFH alloys in both AB and HT conditions were similar, the ductility of IN718-YFH was ~50 % less in almost all conditions compared to the ductility of IN718-YF. This has been shown to be as a result of irregular shaped micron-sized Y-Hf-O oxides, martensite formation in AB condition, increased amount of carbides and existence of secondary γ' particles in HT condition in IN718-YFH. High density of stacking faults (SF) forming at the interface of the nano-oxides have been detected in IN718-YF alloys. Besides dislocation/nanoparticle interactions, SFs which are responsible for the delocalization of the deformation improve the ductility of IN718-YF alloys. Overall, high temperature mechanical tests exhibit that both alloys have higher strength with improved ductility compared to the standard IN718 alloys, indicating the contribution of the nano-oxides.

36 MATERIALS SCIENCE↗

Influence of weave architecture on mechanical response of SiC f -SiC m tubular composites

Due to their high resistance to radiation damage and elevated temperature, silicon carbide fiber-reinforced, silicon carbide matrix composites (SiC f -SiC m ) are identified as potential cladding structures for use in nuclear reactors. In this study, four composite architectures with varying ply numbers along the thickness direction and different biaxial or triaxial plain weave orientations at either 45° or 60°, were systematically evaluated under various stress states to assess the influence of weave architecture on mechanical performance. Experiments were conducted on SiC f -SiC m composite tubes under tensile hoop, axial compression, and rotating flexural loading to evaluate the mechanical response and investigate the failure modes using high-speed imaging and digital image correlation (DIC) techniques. It was found that for tensile hoop burst and flexural loading, the braiding angle had the most significant influence on the strength of the composite, whereas the effect of fiber angle was more limited for compression testing. Under axial compression a unique failure mode where a microcrack nucleates and grows only to a length equal to the thickness of a single yarn was identified. This crack growth behavior is reflected as periodic oscillations in the load-displacement response. For both axial and hoop loading, regardless of weave angle and number of plies, failure always initiated parallel to the tube axis in a single yarn and the cumulative interaction of these microcracks lead to either axial burst or fracture at an angle to the tube axis along a yarn. Furthermore, these results point to the importance of customizing the design of tube architecture for enhanced performance in specified nuclear applications.

36 MATERIALS SCIENCE↗

Radiation response of a Fe–20Cr–25Ni austenitic stainless steel under Fe 2+ irradiation at 500 °C

The radiation response of a Fe–20Cr–25Ni austenitic stainless steel under self-ion irradiation at 500 °C was systematically investigated. The steel was irradiated at 500 °C by 3.5 MeV Fe 2+ ions to 10, 50, and 150 peak dpa, respectively. In the 200–400 nm depth region, radiation-induced Frank loops were relatively stable in both size and number density from 10 to 150 peak dpa. Anisotropic distribution of Frank loops was observed in the 50 and 150 peak dpa specimens, possibly due to interaction of Frank loops and network dislocations with preferred orientations. Coarse voids were found only in the 50 and 150 peak dpa specimens in depths less than 750 nm, suggesting that injected interstitials at deeper regions suppressed the void nucleation. The peak swelling was very low (~0.4%) for both 50 and 150 peak dpa irradiation. Radiation also led to the formation of intragranular plate-like Cr-rich carbides. Radiation-induced segregation of Ni and Si was found at various sinks: dislocation loops, void surfaces, and carbide-matrix interfaces. Finally, irradiation hardening was measured by nanoindentation and the results are consistent with microstructure-based calculations using the dispersed barrier hardening model. The major contributor to irradiation hardening changed from Frank loops at the lowest dose to network dislocations at the highest dose.

dislocation loops↗

Strength stability at high temperatures for additively manufactured alumina forming austenitic alloy

Several fast-spectrum nuclear reactors designed to generate high power (~450 MWe) rely on forced convection of media such as supercritical CO 2 , sodium, or liquid lead to cool the nuclear core, operating at temperatures up to 600 °C. Cost-effective, high-strength Fe-based alumina forming austenitic (AFA) alloys are a promising candidate for the fabrication of critical nuclear components. This study investigated laser powder bed fusion (LPBF) processing of an AFA alloy composition optimized for improved creep resistance. Electron microscopy revealed an elongated grain structure along the build direction with a fine sub-grain cellular structure decorated with (Cr,Fe,Nb) 23 C 6 carbide precipitates at the intercellular boundaries. Finally, at temperatures of 20–900 °C, the LPBF alloy's superior tensile properties compared to its arc-melted counterpart and other advanced steels (e.g., SS316) were attributed to the distribution of nano-sized carbide precipitates, whereas the high ductility was attributed to the LPBF alloy's elongated grain structure.

36 MATERIALS SCIENCE↗

Geometry and size dependent microstructure and crack formation in Rene 41 superalloy fabricated by laser powder bed fusion

This study provides a systematic investigation into the size and geometry-dependent microstructural evolution and cracking susceptibility of LPBF-fabricated Rene 41. By coupling experimental microstructural analysis with thermal modeling, this research uniquely identifies the relationship between geometry-specific thermal histories, carbide coarsening, and liquation cracking. Four different geometries with varying thickness were fabricated with the identical process parameters. It was found that the grain size and morphology are not affected by the part size. However, the thinner parts exhibited coarser sub-grain structures compared to the thicker ones. The crack formation was observed for the parts with cross-sections smaller than 1 mm, whereas thicker parts had high density without any defects. Further, the cracks were observed in the interdendritic regions, suggesting that liquation cracking was the active micro-crack formation mechanism. The detailed microstructural analysis combined with a thermal finite element analysis proved that the heat extraction efficiency was lower for thinner parts causing a lower cooling rate and coarser carbides, making them more susceptible to constitutional liquation. Microhardness measurements were conducted for each geometry and correlated with the observed microstructural variations. The findings highlight the critical need for geometry-specific optimization of LPBF process parameters to mitigate cracking and achieve microstructural uniformity, offering valuable insights into the fabrication of complex, high-performance aerospace components.

36 MATERIALS SCIENCE↗

Estimation of cutting tool wear using an elastomeric tactile sensor

Machining performance of cutting tools and part quality are affected by the geometric condition of the cutting edge, which is influenced by thermomechanical loads experienced during the process. Tool condition monitoring (TCM) systems provide insight for timely replacement of cutting tools. However, existing TCM systems are expensive and require specialized equipment or sensors, hindering widespread adoption. A novel TCM system is developed herein using an elastomeric tactile sensor. Sensor images of the cutting edge are used to quantify wear using two distinct algorithms. In the first algorithm, the unworn and worn edges are identified based on Canny edge detect. In the second, the unworn edge is identified using edge detection while the region of wear is identified using a relative intensity method. In both cases, the maximum wear width is calculated based on an experimentally determined pixel to-physical distance scale. The TCM system is first used to estimate flank wear on a solid carbide helical end mill before evaluating its robustness by employing it to estimate insert wear of an indexable helical end mill. Measurements are also performed manually using an optical microscope and a high-resolution focus variation microscope for verification. The novel technique estimates flank wear in the solid carbide tool with a high accuracy of 98%. Larger discrepancies are observed for the inserts, however, with overlapping uncertainties. In conclusion, the technique shows promise in adaptability, automation, and closed loop control of machine tools.

Machining↗

Synthesis and Electronic Structure of a 3D Crystalline Stack of MXene-Like Sheets

Despite the interest in MXenes in the past decade, MXenes are often highly disordered, which can complicate their study and use. For example, nearly all MXenes have a random mixture of surface terminations (-O, -OH, -F). In addition, restacked 3D films have turbostratic disorder and often contain ions, solvent, and other species in between their layers. Here, we report Y 2 CF 2 , a layered crystal with a unit cell isostructural to a MXene, in which layers are capped only by fluoride anions. We directly synthesize the 3D crystal through a high-temperature solid-state reaction, which affords the 3D crystal in high yield and purity and ensures that only fluoride ions terminate the layers. We characterize the crystal structure and electronic properties using a combination of experimental and computational techniques. We find that relatively strong electrostatic interactions bind the layers together into a 3D crystal and further find that the lack of orbital overlap between layers gives rise to a description of Y 2 CF 2 as slabs of MXene-like sheets electrically insulated from one another. Therefore, we consider Y 2 CF 2 as a pure 3D crystalline stack of MXene-like sheets. In addition, Y 2 CF 2 is the first transition metal carbide fluoride experimentally synthesized. Finally, we hope this work inspires further exploration of transition metal carbide fluorides, which are potentially a large and useful class of compositions.

36 MATERIALS SCIENCE↗

LaNi x Fe 1– x O 3–δ as a Robust Redox Catalyst for CO 2 Splitting and Methane Partial Oxidation

The current study reports LaNi 0.5 Fe 0.5 O 3–δ as a robust redox catalyst for CO 2 splitting and methane partial oxidation at relatively low temperatures (~700 °C) in the context of a hybrid redox process. Specifically, perovskite-structured LaNi x Fe 1–x O 3–δ (LNFs) with nine different compositions (x = 0.05–0.5) were prepared and investigated. Among the samples evaluated, LaNi 0.4 Fe 0.6 O 3–δ and LaNi 0.5 Fe 0.5 O 3–δ showed superior redox performance, with ~90% CO 2 and methane conversions and >90% syngas selectivity. The standalone LNFs also demonstrated performance comparable to that of LNF promoted by mixed conductive Ce 0.85 Gd 0.1 Cu 0.05 O 2–δ (CGCO). Long-term testing of LaNi 0.5 Fe 0.5 O 3–δ indicated that the redox catalyst gradually loses its activity over repeated redox cycles, amounting to approximately 0.02% activity loss each cycle, averaged over 500 cycles. This gradual deactivation was found to be reversible by deep oxidation with air. Further characterizations indicated that the loss of activity resulted from a slow accumulation of iron carbide (Fe 3 C and Fe 5 C 2 ) phases, which cannot be effectively removed during the CO 2 splitting step. Reoxidation with air removed the carbide phases, increased the availability of Fe for the redox reactions via solid-state reactions with La 2 O 3 , and decreased the average crystallite size of La 2 O 3 . As a result, reactivating the redox catalyst periodically, e.g., once every 40 cycles, was shown to be highly effective, as confirmed by operating the redox catalyst over 900 cumulative cycles while maintaining satisfactory redox performance.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

One-Pot Coating of Ceramic Powders by Exfoliated Boron Nitride Layers with a Dense CO 2 Medium and Ultrasound-Aided Mixing

The coating or doping of substrates by two-dimensional materials to impart superior functional properties (such as improved thermal conductivity, bacterial resistance, reduced friction) is receiving increased attention. Environmentally benign, rapid and scalable coating techniques are desirable for this purpose. Here, we report a novel process for coating alumina, silicon carbide and boron carbide substrates with hexagonal boron nitride (h-BN) layers. The process consists of two sequential steps. First, h-BN layers are exfoliated from bulk h-BN in supercritical carbon dioxide (scCO 2 ) using ultrasound-aided mixing. This step is followed by self-assembly (i.e., coating) of the exfoliated h-BN on the substrates in liquid CO 2 also aided by ultrasound. The liquid CO 2 state is achieved by simply lowering the pressure and temperature of the first step below the critical point of CO 2 (P c = 72.8 atm; T c = 31.1 °C). Scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS) micrographs clearly reveal the exfoliation of h-BN under scCO 2 conditions as well as the h-BN assembly on various substrates under liquid CO 2 conditions. X-ray diffraction patterns confirm the structural integrity of the coated h-BN layers. It was also confirmed that without a transition to the liquid CO 2 phase following exfoliation in scCO 2 , there was negligible coating of h-BN on the substrates. Researchers in the field could consider this benign process to rapidly coat or dope materials with h-BN and other 2D materials to impart improved functional properties in myriad applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Monte Carlo Explicitly Correlated Second-Order Many-Body Green’s Function Calculations of Semiconductor Band Gaps

A systematically converging series of ab initio, post-density-functional, size-consistent, electron-correlated approximations is desired for predictive computing of felectronic band structures of insulating, semiconducting, and metallic solids. A series that meets all of these desiderata (except the applicability to metals) is ab initio many-body Green's function theory based on Gaussian-type-orbital (GTO) basis sets. Here, its leading-order approximation, the second-order Green's function (GF2) method in the diagonal and frequency-independent approximations with the aug-cc-pVDZ basis set, is applied to the fundamental band gaps of three semiconductors (diamond, silicon, and silicon carbide in the zincblende structure) using cluster models. Corrections are made to the basis-set-incompleteness errors by the explicit-correlation (F12) ansatz (GF2-F12) for the valence band edges. The crystals are modeled as surface-passivated clusters of increasing sizes, whose wave functions are expanded by up to 2709 GTO basis functions. Immense computational costs of these calculations are overcome by the highly scalable stochastic algorithm of the Monte Carlo GF2-F12 method, whose operation cost per state increases only as a cubic power of system size, which has a tiny memory footprint and easily achieves near-perfect parallel efficiency on thousands of CPUs or on hundreds of GPUs. The correlated, F12-corrected highest-occupied and lowest-unoccupied molecular-orbital energy (HOMO-LUMO) gap is 5.78 ± 0.07 eV for C 87 H 76 as compared with the experimental value of the fundamental (indirect) band gap of bulk diamond at 5.48 eV. The correlated, F12-corrected HOMO-LUMO gaps for Si 75 H 76 and Si 32 C 43 H 76 are 2.56 ± 0.15 eV and 3.50 ± 0.12 eV, respectively, which are expected to decrease further with increasing cluster sizes. As a result, the experimental fundamental (indirect) band gaps of bulk silicon and silicon carbide are 1.17 eV and 2.42 eV, respectively.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

Insights into Spontaneous Solid Electrolyte Interphase Formation at Magnesium Metal Anode Surface from Ab Initio Molecular Dynamics Simulations

Spontaneous chemical reactivity at multivalent (Mg, Ca, Zn, Al) electrode surfaces is critical to solid electrolyte interphase (SEI) formation, and hence, directly affects the longevity of batteries. Here, we report an investigation of the reactivity of 0.5 M Mg(TFSI)2 in 1,2-dimethoxyethane (DME) solvent at a Mg(0001) surface using ab initio molecular dynamics (AIMD) simulations and detailed Bader charge analysis. Based on the simulations, the initial degradation reactions of the electrolyte strongly depend on the structure of the Mg(TFSI)2 species near the anode surface. At the surface, the dissociation of Mg(TFSI)2 species occurs via cleavage of the N-S bond for the solvent separated ion pair (SSIP) and via cleavage of the C-S bond for the contact ion pair (CIP) configuration. In the case of the CIP, both TFSI anions undergo spontaneous bond dissociation reactions to form atomic O, C, S, F, and N species adsorbed on the surface of the Mg anode. These products indicate that the initial SEI layer formed on the surface of the pristine Mg anode consists of a complex mixture of multiple components such as oxides, carbides, sulfides, fluorides, and nitrides. We believe that the atomic level insights gained from these simulations will lay the groundwork for the rational design of tailored and functional interphases that are critical for the success of multivalent battery technology.

Agarwal, Garvit↗

Promotional Effect of ZnO and ZrO 2 in K-Doped Fe Catalysts for CO 2 Hydrogenation to Light Olefins

Promoters play a critical role in tuning the activity and selectivity of Fe catalysts in CO 2 hydrogenation to produce light olefins, which are key building blocks in the petrochemical industry. Herein, by a combined experimental and theoretical approach, we show that high and stable performance of Fe catalysts could be achieved by taking advantage of the promotional effect of both Zn and Zr. Structural characterization indicates that ZnO could improve the dispersion and reducibility of Fe oxides and facilitate the formation of active Fe carbide species, whereas ZrO 2 could stabilize the structure and catalytic performance, especially the selectivity of hydrocarbon products. In situ diffuse reflectance infrared Fourier transform spectroscopy (DRIFTS) experiments suggest that carbonate, bicarbonate, formate, and methoxy are essential intermediates in the CO 2 hydrogenation to hydrocarbon products, including paraffins and olefins. The conversion kinetics of each intermediate species are dependent on the type of promoters as well as the phase structure of the active Fe species. DFT calculations revealed a strong correlation between the formation energy of surface oxygen vacancies and that of Fe carbide species in promoted Fe oxides, in accordance with experimental results. Moreover, the calculated energy profiles of CO 2 hydrogenation over different catalysts indicate that Zn could promote the activation of CO 2 and its transformation to the oxygenate intermediates, while Zr could facilitate the conversion of oxygenates to hydrocarbon precursors. Finally, the discrepancies in the evolution trend of various intermediate species on promoted Fe catalysts in the transient DRIFTS experiments can be rationalized by the differences in energy barriers of elementary or rate limiting steps.

CO2 conversion↗

Material Characterization-Based Wear Mechanism Investigation for Biomass Hammer Mills

Biomass, as harvested, is composed of inorganic compounds both intrinsically and extrinsically and can be abrasive. The present study investigates the wear modes and mechanisms of two types of blades of hammer mills used in biomass size reduction (impacting the particle size and distribution) and densification (impacting the size, shape, and density). The dominant wear modes for the stage 1 steel blades are determined to be erosive and polishing wear. For the stage 2 blades with a carbide weld overlay, the main wear mechanisms are erosion and fracture. Partial replacement of Co by Fe in the outer layer of the carbide grits, likely induced by diffusion during high-temperature welding, has been correlated to the observed microcracking. Finally, the microcracking is believed to weaken the grit strength and fracture toughness to make the overlay prone to fracture and erosion due to repetitive contact with the inorganic contents in chopping biomass.

42 ENGINEERING↗

USc 2 C 2 and USc 2 NC Clusters with U–C Triple Bond Character Stabilized Inside Fullerene Cages

The chemistry of f-block metal–carbon multiple bonds is underdeveloped compared to well-established carbene complexes of the d-block transition metals. Herein, we report two new actinide-rare earth mixed metal carbides and nitrogen carbide cluster fullerenes, USc 2 C 2 @D 5h (6)-C 80 and USc 2 NC@D 5h (6)-C 80 , which contain U–C bonds with triple bond character and were successfully synthesized and characterized by mass spectrometry, UV–vis–NIR spectroscopy, Fourier transform infrared spectroscopy, single crystal X-ray diffraction, and DFT calculations. Crystallographic studies show that the two previously unreported clusters, USc 2 C 2 and USc 2 NC, are stabilized in the D 5h (6)-C 80 carbon cage and adopt unique trifoliate configurations, in which C 2 /NC units are almost vertically inserted into the plane defined by the U and two Sc atoms. Combined experimental and theoretical studies further reveal the bonding structure of USc 2 C 2 and USc 2 NC, which contain C=U(VI)=C and C=U(V)=N bonding motifs. The electronic structures of the two compounds are determined as U 6+ (Sc 2 ) 6+ (C 4– ) 2 @D 5h (6)-C 80 4– and U 5+ (Sc 2 ) 6+ (N) 3– (C) 4– @D 5h (6)-C 80 4– , respectively. Quantum-chemical studies confirm that the U–C bonds in both molecules show unprecedented multicenter triple-bond character. Furthermore, the discovery of this unique U–C multiple bond offers a deeper understanding of the fundamentals of uranium chemistry.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Understanding the interface interaction between U3Si2 fuel and SiC cladding

Abstract Triuranium disilicide (U 3 Si 2 ) fuel with silicon carbide (SiC) composite cladding is being considered as an advanced concept/accident tolerant fuel for light water reactors thus, understanding their chemical compatibility under operational and accident conditions is paramount. Here we provide a comprehensive view of the interaction between U 3 Si 2 and SiC by utilizing density functional theory calculations supported by diffusion couple experiments. From the calculated reaction energies, we demonstrate that triuranium pentasilicide (U 3 Si 5 ), uranium carbide (UC), U 20 Si 16 C 3 , and uranium silicide (USi) phases can form at the interface. A detailed study of U 3 Si 2 and SiC defect formation energies of the equilibrated materials yielding the interfacial phases U 20 Si 16 C 3 , U 3 Si 5 and UC reveal a thermodynamic driving force for generating defects in both fuel and cladding. The absence of either the U 3 Si 2 or SiC phase, however, causes the defect formation energies in the other phase to be positive, removing the driving force for additional interfacial reactions. The diffusion couple experiments confirm the conclusion with demonstrated restricted formation of U 3 Si 5 , UC, and U 20 Si 16 C 3 /USi phases at the interface. The resulting lack of continuous interaction between the U 3 Si 2 and SiC, reflects the diminishing driving force for defect formation, demonstrating the substantial stability of this fuel-cladding system.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Engineering the formation of spin-defects from first principles

The full realization of spin qubits for quantum technologies relies on the ability to control and design the formation processes of spin defects in semiconductors and insulators. We present a computational protocol to investigate the synthesis of point-defects at the atomistic level, and we apply it to the study of a promising spin-qubit in silicon carbide, the divacancy (VV). Our strategy combines electronic structure calculations based on density functional theory and enhanced sampling techniques coupled with first principles molecular dynamics. We predict the optimal annealing temperatures for the formation of VVs at high temperature and show how to engineer the Fermi level of the material to optimize the defect’s yield for several polytypes of silicon carbide. Our results are in excellent agreement with available experimental data and provide novel atomistic insights into point defect formation and annihilation processes as a function of temperature.

36 MATERIALS SCIENCE↗