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At least 595 records · Page 33

Minimum feature size control in level set topology optimization via density fields

A level set topology optimization approach that uses an auxiliary density field to nucleate holes during the optimization process and achieves minimum feature size control in optimized designs is explored. The level set field determines the solid-void interface and the density field describes the distribution of a fictitious porous material using the solid isotropic material with penalization. These fields are governed by two sets of independent optimization variables which are initially coupled using a penalty for hole nucleation. The strength of the density field penalization and projection is gradually increased during the optimization process to promote a 0-1 density distribution. In addition, a second penalty regulates the evolution of the density field in the void phase. The treatment of the density field combined with the second penalty mitigate the appearance of small design features. The minimum feature size of optimized designs is controlled by the radius of the linear filter applied to the density optimization variables. The structural response is predicted by the extended finite element method, the sensitivities by the adjoint method, and the optimization variables are updated by a gradient-based optimization algorithm. Numerical examples investigate the robustness of this approach with respect to algorithmic parameters and mesh refinement. The results show the applicability of the combined density level set topology optimization approach for both optimal hole nucleation and for minimum feature size control in 2D and 3D. This comes, however, at the cost of a more complex problem formulation and additional computational cost due to an increased number of optimization variables.

42 ENGINEERING↗

Quantifying Equiaxed vs Epitaxial Solidification in Laser Melting of CMSX-4 Single Crystal Superalloy

The competition between epitaxial vs. equiaxed solidification has been investigated in CMSX-4 single crystal superalloy during laser melting as practiced in additive manufacturing. Single-track laser scans were performed on a powder-free surface of directionally solidified CMSX-4 alloy with several combinations of laser power and scanning velocity. Electron backscattered diffraction (EBSD) mapping facilitated identification of new orientations, i.e., “stray grains” that nucleated within the fusion zone along with their area fraction and spatial distribution. Using high-fidelity computational fluid dynamics simulations, both the temperature and fluid velocity fields within the melt pool were estimated. This information was combined with a nucleation model to determine locations where nucleation has the highest probability to occur in melt pools. In conformance with general experience in metals additive manufacturing, the as-solidified microstructure of the laser-melted tracks is dominated by epitaxial grain growth; nevertheless, stray grains were evident in elongated melt pools. It was found that, though a higher laser scanning velocity and lower power are generally helpful in the reduction of stray grains, the combination of a stable keyhole and minimal fluid velocity further mitigates stray grains in laser single tracks.

36 MATERIALS SCIENCE↗

Creep ductility limiting mechanisms in an additively manufactured Al-Ce-Ni-Mn-Zr alloy

Tensile creep response and cavitation damage evolution in an additively manufactured Al-7.5Ce-4.5Ni-0.4Mn-0.7Zr (wt%) alloy with peak-aging and overaging treatments were investigated in the 300–400 ºC range. Microstructural heterogeneity and its response to heat treatment and subsequent creep deformation were studied to understand the interplay between cavity formation, creep lifetime and ductility. Increasing the applied stress activated the nucleation of more cavities, an experimental observation that is well described using the vacancy accumulation model. Cavities nucleated prematurely due to localized plasticity in the denuded zones that formed at/near melt-pool or grain boundaries. Microstructure/deformation heterogeneity with consequent evolution of stress triaxiality, especially at lower stresses, causes accelerated cavitation, thus producing low creep ductility (∼ 0.2–2.4 %), compared to (∼12–21 %) ductility of the alloy measured by regular tensile tests at equivalent temperatures. A constrained diffusional cavity growth mechanism with continuous cavity nucleation during creep is established as the dominant mechanism, implying that cavitation involves vacancy diffusion, yet its growth rate is dictated by the minimum creep rate. In conclusion, the ductility-limiting creep and cavitation mechanisms discussed here provide new insight into the creep behavior of 3D-printed metallic alloys.

Additive manufacturing↗

Critical heat flux on zircaloy and accident tolerant fuel cladding under prototypical conditions of pressurized and boiling water reactors

First of a kind high spatial and temporal resolution temperature measurements of Pressurized Water Reactor and Boiling Water Reactor simulated fuel pins (high heat flux cosine profile heaters) in annular rod type geometry during nucleate boiling, departure from nucleate boiling and re-wetting has been performed. Distributed fiber optic measurements of the cladding axial temperature with spatial resolutions down to 2.5 mm axially at up to three equally spaced azimuthal locations per rod have demonstrated the similarities and differences of the different accident tolerant fuel cladding materials. These experiments show the performance of accident tolerant cladding with a precise measurement of the location and evolution of dryout followed by the re-wetting phenomena (see supplementary time history of a critical heat flux event). Experimental parameters varied coolant mass fluxes from 1695 to 2712 kg/m 2 s, pressures from 10 to 20 MPa, and inlet subcooling from 10 to 55 °C. It was found that the coatings and different material have little effect on the value of the critical heat flux. Any discrepancies between the local critical heat flux verified among the cladding material are attributed to different departure from nucleate boiling phenomena captured during the experiment with the high-resolution optical fiber temperature data. Substantial differences in the performance of the different cladding material to survive a critical heat flux event were however observed by post-test X-ray and optical inspection. External evident damage and internal cracks to the simulated fuel pin having the bare zircaloy cladding were observed in regions associated with the occurrence of the critical heat flux for longer periods. Such damages were associated with zirconium oxidation, and not noticed on the Cr coated zircaloy or FeCrAl claddings. These results indicate that the use of FeCrAl or a Cr coated zircaloy as cladding in Pressurized Water Reactor and Boiling Water Reactor may increase the survivability of the cladding material for short transients.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

A microstructural signature of the coesite-quartz transformation: New insights from high-pressure experiments and EBSD

Ultra-high pressure (UHP) metamorphism is difficult to identify in continental crust as few petrological barometers are suitable for dominantly felsic lithologies. In such cases, burial to extreme depths is commonly identified through the preservation of coesite, a high-pressure polymorph of SiO 2 that typically forms at depths exceeding ∼ 100 km (i.e., > 2 GPa pressure). Unfortunately, coesite readily transforms to quartz upon exhumation, meaning that UHP terranes may often be overlooked. While some studies have suggested that quartz may inherit an orientation signature indicative of former coesite, both the specific nature of this signature and the conditions favouring its development remain uncertain. Here, to address this problem, we combine electron backscatter diffraction analysis of natural and experimental samples to explore microstructural evolution across the coesite-quartz phase transformation. We demonstrate that neighbouring domains of quartz commonly feature an 84 ± 4° rotation of [c] axes around the pole of a common {m} plane. This orientation relationship is a product of epitaxy, whereby the {$11\bar{2}2$} Japan twin plane in quartz nucleates on the (010) plane in coesite. In supercell simulations, the nucleation of Japan twins can be explained by the energetically favourable alignment of quartz tetrahedra on parental coesite tetrahedra. Through experiments, we demonstrate that this signature emerges over a broad range of conditions, regardless of the availability of nucleation sites (e.g., grain boundaries) or the density of crystal lattice defects (e.g., dislocations). Overall, our work provides a quantitative and unambiguous tool for identifying UHP terranes from quartz in isolation.

Coesite↗

Elucidating the Impact of Flow on Material-Sensitive Critical Heat Flux and Boiling Heat Transfer Coefficients: An Experimental Study with Various Materials

In this work, steady-state internal flow boiling critical heat flux (CHF) experiments were carried out at 10°C inlet subcooling and atmospheric pressure (84 kPa at an altitude of about 5300 feet) with mass flux ranging from 200 to 2,000 kg/m 2 -s on seven tube materials, including the accident-tolerant fuel cladding candidate FeCrAl (C26M) alloy. At a relatively low flow rate, the sensitivity of CHF to different materials was appreciable (the average difference among the tested materials was 19% at 200 kg/m 2 -s). As the absolute CHF differences stayed constant for higher flow rates, the increased flow rate led to reduced relative CHF differences among the tested materials (average relative difference of 15% at 1,000 kg/m 2 -s). FeCrAl alloy claddings that were oxidized under simulated Light Water Reactor (LWR) conditions yielded CHF comparable to as-received FeCrAl alloy cladding, with less than 1.8% difference. Experimental CHF results imply marginal material sensitivity impacts on the departure from nucleate boiling ratio in steady-state nuclear reactor cores. Yet, for accident progression analysis, material sensitivity may hold importance, as boiling behavior variation at low mass flux is appreciable. Macroscopic material parameters (surface wettability, surface roughness, and thermal properties) do not provide a suitable explanation for observed material-sensitive CHFs. Yet, surface roughness and thermal effusivity revealed power and linear relations, respectively, to the nucleate boiling heat transfer coefficients at low mass flux. At high mass flux, material sensitivity on nucleate boiling heat transfer significantly decreased due to the increased shear stress on boiling surface overwhelming material-related boiling implications.

36 MATERIALS SCIENCE↗

Primary solidification of ternary compounds in Al-rich Al–Ce–Mn alloys

Primary solidification of ternary compounds Al 20 Mn 2 Ce and Al 10 Mn 2 Ce were analyzed through the coupling of the thermodynamic modeling and classic nucleation theory. Thermodynamic models of Al 20 Mn 2 Ce and Al 10 Mn 2 Ce were developed using the CALPHAD approach based on first-principles calculated enthalpy of formation and experimental data obtained from this work and the literature. The analysis suggested that despite the larger thermodynamic driving force for nucleation of Al 10 Mn 2 Ce, nucleation is preferred for the Al 20 Mn 2 Ce phase in the highly undercooled liquid due to its smaller interfacial energy. Therefore, manufacturing methods with rapid cooling rates will favor primary solidification of Al 20 Mn 2 Ce for Al-rich Al–Ce–Mn alloys.

36 MATERIALS SCIENCE↗

The mobility of small, over-pressurized helium bubbles in tungsten at 2000 K

Fusion reactor environments inevitably lead to the formation of high-pressure helium bubbles whose nucleation, growth, and diffusion strongly impact the performance of plasma-facing components. Here this research describes a diffusion mechanism of over-pressurized bubbles via a sequence of Frenkel pair nucleation, self-interstitial migration, and Frenkel pair annihilation. Molecular dynamics was used to simulate the diffusion of small bubbles in tungsten at 2000 K with helium-per-vacancy ratios in the range of 4.5 to 7. The diffusion coefficients are calculated and their dependence on helium content, number of vacancies, and number of attached self-interstitials is characterized. It is found that bubbles are most mobile when the nucleation/annihilation rates of Frenkel pairs are nearly equal and when the bubbles nucleate and annihilate a single self-interstitial. All bubbles experience a peak diffusivity, which can be as high as 10 -11 m 2 /s decreasing with bubble size. The calculated diffusion coefficients provide valuable insight into the mobility of small, high-pressure bubbles, and can be used as input parameters in mesoscale models to improve predictions of plasma-surface interactions. (LA-UR-21-21881)

36 MATERIALS SCIENCE↗

Cluster dynamics modeling of Mn-Ni-Si precipitates coupled with radiation-induced segregation in low-Cu reactor pressure vessel steels

Formation of precipitates enhanced or induced by irradiation causes hardening and embrittlement of nuclear structural materials. Post-irradiation microstructure characterization of reactor pressure vessel (RPV) steels has shown that precipitation can be strongly associated with radiation-induced segregation (RIS) of solutes on dislocations. However, RIS and precipitation have not been coupled in previous precipitation modeling of RPV steels. Here in this study, a new hybrid and spatially-dependent precipitation model is developed that couples cluster dynamics with RIS, providing an unique way to account for concurrent evolution of heterogeneous cluster densities as well as solute and point defect concentration profiles. The model is applied to study the segregation of Mn, Ni, and Si on dislocations and heterogeneous nucleation of Mn-Ni-Si rich precipitates (MNSPs) in a low-Cu RPV steel. The result shows that the onset of MNSP nucleation on dislocations occurs at the fluence of 2 x 10 23 n.m -2 . The number density and mean radius can reach ~ 10 24 m -3 and 1-2 nm at high fluence, respectively. These observations suggest that the role of RIS and heterogeneous nucleation can be significant for RPV steels under a high fluence of irradiation. Results of simulations adopting various dose rates and dislocation densities show an increased fraction of MNSPs on dislocations at the condition of low dose rate, high dislocation density, and high fluence.

36 MATERIALS SCIENCE↗

Kinetics of moisture-induced phase transformation in inorganic halide perovskite

The high-temperature (high-T) phase of cesium lead iodide (CsPbI 3 ) presents great promise for photovoltaic applications; however, exposure to ambient moisture at room temperature transforms it into its less-desirable low-temperature (low-T) phase with a larger band gap. While there have been theoretical predictions on the influence of moisture level on the phase transformation kinetics, the corresponding quantitative experimental evidence has remained limited. Tracking CsPbI 3 phase transformation under controlled relative humidity (RH), we find that rising RH increases the nucleation rate of low-T CsPbI 3 exponentially, but has a weak effect on its growth. The overall transformation is nucleation limited, with higher RH leading to a lower nucleation barrier. Finally, we find that heating between 40°C and 80°C facilitates water desorption and suppresses phase transformation. Our findings elucidate the relationship between moisture and the phase energetics of CsPbI 3 , which can serve as references for thin film applications of CsPbI 3 and future designs of stable photovoltaics systems.

36 MATERIALS SCIENCE↗

Spatiotemporal Route to Understanding Metal Halide Perovskitoid Crystallization

Here, a spatiotemporal experimental route is reported for the antisolvent vapor diffusion crystal growth of metal halide perovskitoids. A computational analysis combining automated image capture and diffusion modeling enables the determination of the critical concentrations required for nucleation and crystal growth from a single experiment. Five different solvent systems and ten distinct organic ammonium iodide salts were investigated with lead iodide, from which nine previously unreported compounds were discovered. Automated image capture of the mother liquor and antisolvent vials was used to determine changes in solution meniscus positions and detect the nucleation event location. Matching the observations to a numerical solution of Fick's second law diffusion model enables the calculation of reactant, solvent, and antisolvent concentrations at both the time and position of the first stable nucleation and crystal growth. A machine learning model was trained on the resulting data, and it reveals solvent- and amine-specific crystallization tendencies. Solvent systems that interact more weakly with dissolved lead species promote crystallization, while those with stronger interactions can prevent crystallization through increased solubilities. Organic amines that interact more strongly with inorganic components and exhibit greater rigidity are more likely to be incorporated into crystalline products.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Effect of the Precursor Chemistry on the Crystallization of Triple Cation Mixed Halide Perovskites

Triple cation, mixed halide perovskite compositions have been reported to be more thermally stable, exhibit fewer phase impurities, and show higher power conversion efficiency and better reproducibility than single cation perovskites. In this work, we explain the formation of Cs0.05FA0.81MA0.14Pb(I0.85Br0.15)3 via a multimodal in situ study combining structural information from synchrotron grazing-incidence wide-angle X-ray scattering (GIWAXS) and optical properties from photoluminescence (PL) spectroscopy with density functional theory calculations (DFT). The focus here is on the effects of the solvent and antisolvent during crystallization. The predominantly used solvents N,N-dimethylformamide (DMF), dimethyl sulfoxide (DMSO), and the antisolvent chlorobenzene (CB) as well as the solvent-antisolvent-precursor interactions are investigated. Given the high elemental complexity and mutual interdependencies between solvent, antisolvent, and perovskite precursors, we found significant differences in the crystallization pathways. DMF-pure precursors show the formation of the DMF-containing intermediate phase and the nucleation of compositionally distinct perovskite phases, while when DMSO is added, only crystalline α- and δ-phases were found. In addition, the presence of DMSO helps the formation of α-perovskite. Coordination energy and bond order (BO) calculations support our experimental findings. Dripping of CB induces nucleation at room temperature, slows the α-phase formation rate, and appears to reduce the nucleation radius. These findings provide novel insights into solvent, antisolvent, and perovskite precursor interactions and their formation pathways. The complexity of interactions between solvents and reagents highlights the importance of understanding these effects to further improve the reproducibility and optimize processing conditions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Isoconversional Kinetic Analysis of Oxygen Desorption for Sr 0.75 Ca 0.25 FeO 3-δ Perovskite in Dry and Steam-Based Environments

The desorption kinetics of Sr 0.75 Ca 0.25 FeO 3-δ perovskite material are examined in both dry and steam-based environments using redox gaseous products of a laboratory-scale fixed bed. First, desorption kinetics associated with the dry environment are proposed based on Friedman’s isoconversional method. It is found from the reconstructed reaction model that the desorption kinetics of this perovskite are controlled by a three-step mechanism, where hypothetically, the phase-boundary reaction rapidly prevails first, followed by diffusion and/or nucleation, and finally, unimolecular decay or random nucleation-controlled reaction. Subsequent analyses of the Arrhenius parameters indicated that both the early and later desorption stages, respectively, controlled by the phase boundary and unimolecular/random nucleation reactions, are associated with low energetic demand. In contrast, a high energetic penalty is required for the diffusion/nucleation reaction. Further, a satisfactory a priori verification of the proposed kinetics suggested that the three-step reaction mechanism reasonably describes the desorption of this perovskite in a dry environment. With the presence of steam in the desorption environment, oxygen production is substantially inhibited, but the hypothetical three-step mechanism is still found to control the desorption. Meanwhile, the primary effects of the steam on these mechanisms include the widening of the conversion extent associated with the diffusion/nucleation reaction, along with a higher energetic demand compared to the dry environment.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Chemically Driven Multistep Crystallization in the Synthesis of Sodium Yttrium Fluoride Via a Porous, Electrochemically Active Intermediate

Two-step crystallization mechanisms based on liquid–liquid phase separations followed by crystallization are commonly observed both in the laboratory and in nature. While this pathway quite often occurs as a result of a chemical reaction, the subsequent nucleation and growth are often considered as separate, discrete events from the reaction itself. We show this mechanism in the aqueous synthesis sodium yttrium fluoride, but by using a combination of experimental techniques and computational modeling, we show an additional step of solid-state chemical diffusion that is essential to the nucleation mechanism. In this system, we observe at least four distinct steps in the crystallization process, including (1) the segregation of aqueous ions into a dense liquid phase, (2) the formation of a metastable amorphous aggregate, (3) the continuous, gradual solid-state diffusion of sodium and fluoride ions into the amorphous aggregate toward a NaYF4 stoichiometry, and (4) the crystallization of a stable cubic sodium yttrium fluoride phase. Unlike previous descriptions of nucleation and growth, we find that the stoichiometry of the final solid phase evolves throughout the crystallization process rather than being determined at the time of the initial separation from solution. Further, this emphasizes that the chemical reaction cannot be assumed to be a separate event from the phase separation and growth, especially in compounds with variable stoichiometry. We also find that the amorphous aggregate that forms prior to the ion incorporation step adopts a porous, gel-like structure, which we isolated and showed to be electrochemically active, allowing for its potential use as a battery anode in lithium and sodium ion batteries, among other potential applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Polymer-Stabilized Liquid Metal Nanoparticles as a Scalable Current Collector Engineering Approach Enabling Lithium Metal Anodes

Dendrites and dead lithium formation over prolonged cycling have long been challenges that hinder the safe implementation of metallic Li anodes. In this study, we employ polymer-stabilized liquid metal nanoparticles (LM-P NPs) of eutectic gallium indium (EGaIn) to create uniform Li nucleation sites enabling homogeneous lithium electrodeposition. Block copolymers of poly(ethylene oxide) and poly(acrylic acid) (PEO-b-PAA) were grafted onto the EGaIn surface, forming stabilized, well-dispersed NPs. Using a scalable spray coating approach, LM-P NPs were fabricated on copper current collectors, providing lithiophilic PEO sites and interactive carboxyl groups to guide Li deposition. The Li-EGaIn alloying process greatly reduced the Li + diffusion barrier, enabling fast Li transport through the coating layer, resulting in decreased nucleation overpotential. Therefore, about five times lower Li nucleation overpotential was obtained on the LM-P modified Cu with an optimal composition of the polymers than the bare Cu substrates. DFT computations was used to reveal the binding properties between the LM-P layer and Li. Due to the regulated Li plating/stripping process, as-obtained 30 μm Li anodes paired with LiNi 0.8 Co 0.1 Mn 0.1 O 2 (NCM8 11 ) with a negative/positive electrode capacity (N/P) ratio ~ 10 exhibited stable cycling performance at 0.5C for over 250 cycles, with an average Coulombic efficiency of 99.55%. Ultrathin Li (1 μm) anodes with an N/P ratio ~ 0.6 were also demonstrated in Li|LiFePO 4 cells, which examined the stabilization of Li by LM-P NPs and monitored practical loadings of Li anodes that are close to anode-free systems.

25 ENERGY STORAGE↗

The Role of Ice Splintering on Microphysics of Deep Convective Clouds Forming Under Different Aerosol Conditions: Simulations Using the Model With Spectral Bin Microphysics

Observations during the Ice in Clouds Experiment-Tropical (ICE-T) field experiment show that the ice particles concentration in a developing deep convective clouds at the level of T = -15 °C reached about 500 L -1 , that is, many orders higher than that of ice-nucleating particle. To simulate microphysics of these clouds, the 2-D Hebrew University Cloud model (HUCM) with spectral bin microphysics was used in which two main types of ice multiplication mechanisms were included in addition to the Hallet-Mossop mechanism. In the first ice multiplication mechanism ice splinters form by drop freezing and drop-ice collisions. Ice multiplication of this type dominates during developing stage of cloud evolution, when liquid water content is significant. At later stage when clouds become nearly glaciated, ice crystals are produced largely by ice splintering during ice-ice collisions (the second ice multiplication mechanism). Simulations show that droplet size distributions, as well as size distributions of ice particles, agree well with the measurements during ICE-T. Simulations with different cloud condensation nuclei concentrations show the existence of the “optimum” cloud condensation nuclei concentration (or droplet concentration), at which concentration of ice splinters reaches maximum. In these simulations ice nucleation caused by the direct formation of ice crystals upon ice-nucleating particles, as well as the Hallett-Mossop process, has a negligible contribution to the ice crystal concentration.

54 ENVIRONMENTAL SCIENCES↗

Tensile deformation behavior of twist grain boundaries in CoCrFeMnNi high entropy alloy bicrystals

High entropy alloys (HEA) are a class of materials that consist of multiple elemental species in similar concentrations. The use of elements in far from dilute concentrations introduces a multi-dimensional composition design space by which the properties of metallic systems can be tailored. While the mechanical behavior of HEAs has been the subject of active research recently, the role of grain boundaries (GBs) in their deformation behavior remains poorly understood. Motivated by recent experiments on HEAs demonstrating that GBs act as nucleation sites for deformation twins, herein, we leverage atomistic simulations to construct a series of equiatomic CoCrFeMnNi HEA bicrystals with $\langle 110 \rangle$ and $\langle 111 \rangle$ symmetric twist GBs and examine their tensile behavior and underlying deformation mechanisms at 77 K. Simulation results reveal that plastic deformation proceeds by the nucleation of partial dislocations from GBs, which then grow with further loading by bowing into the bulk crystals leaving behind stacking faults. Variations in the nucleation stress exist as function of GB character, defined in this work by the twist angle. Our results provide future avenues to explore GBs as a microstructure design tool to develop HEAs with tailored properties.

36 MATERIALS SCIENCE↗

Crystallization of binary nanocrystal superlattices and the relevance of short-range attraction

The synthesis of binary nanocrystal superlattices (BNSLs) enables the targeted integration of orthogonal physical properties, such as photoluminescence and magnetism, into a single superstructure, unlocking a vast design space for multifunctional materials. However, the formation mechanism of BNSLs remains poorly understood, restricting the prediction of the structure and properties of superlattices. Here we use a combination of in situ scattering and molecular simulation to elucidate the self-assembly of two common BNSLs (AlB 2 and NaZn 13 ) through emulsion templating. Our self-assembly experiments reveal that no intermediate structures precede the formation of the final binary phases, indicating that their formation proceeds through classical nucleation. Using simulations, we find that, despite the formation of AlB 2 and NaZn 13 typically being attributed to entropy, their self-assembly is most consistent with the nanocrystals possessing short-range interparticle attraction, which we find can accelerate nucleation kinetics in BNSLs. Here, we also find homogeneous, classical nucleation in simulations, corroborating our experiments. These results establish a robust correspondence between experiment and theory, paving the way towards prediction of BNSLs.

36 MATERIALS SCIENCE↗