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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 649 records · Page 36
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Case studies of robots and automation as health/safety interventions in small manufacturing enterprises

This article reviews the experiences of 63 case studies of small businesses (<250 employees) with manufacturing automation equipment acquired through a health/safety intervention grant program. The review scope included equipment technologies classified as industrial robots (n = 17), computer numerical control (CNC) machining (n = 29), or other programmable automation systems (n = 17). Descriptions of workers' compensation (WC) claim injuries and identified risk factors that motivated the acquisition of the equipment were extracted from grant applications. Other aspects of the employer experiences, including qualitative and quantitative assessment of effects on risk factors for musculoskeletal disorders (MSD), effects on productivity, and employee acceptance of the intervention were summarized from the case study reports. Case studies associated with a combination of large reduction in risk factors, lower cost per affected employee, and reported increases in productivity were CNC stone cutting system, CNC/vertical machining system, automated system for bottling, CNC/routing system for plastics products manufacturing, and a CNC/Cutting system for vinyl/carpet. Six case studies of industrial robots reported quantitative reductions in MSD risk factors in these diverse manufacturing industries: snack foods; photographic film, paper, plate, and chemical; machine shops; leather goods and allied products; plastic products; and iron and steel forging. Furthermore, this review of health/safety intervention case studies indicates that advanced (programmable) manufacturing automation, including industrial robots, reduced workplace musculoskeletal risk factors, and improved process productivity in most cases.

42 ENGINEERING↗
DOE OSTI2018

SCC Initiation Behavior of Alloy 182 in PWR Primary Water

SCC initiation behavior of 15% cold forged specimens cut from four different alloy 182 weldments was investigated in 360°C simulated PWR primary water under constant load at the yield stress using direct current potential drop to perform in-situ monitoring of SCC initiation time. Within each weldment, one or more specimens underwent SCC initiation within 24 hours of reaching full load while some specimens had much longer initiation times, in a few cases exceeding 2500 hours. Detailed examinations were conducted on these specimens with a focus on different microstructural features such as preexisting defects, grain orientation and second phases, highlighting an important role of microstructure in crack initiation of alloy 182.

Alloy 182↗
DOE OSTI2022

Celestial amplitudes as AdS-Witten diagrams

Both celestial and momentum space amplitudes in four dimensions are beset by divergences resulting from spacetime translation and sometimes scale invariance. In this paper we consider a (linearized) marginal deformation of the celestial CFT for Yang-Mills theory which preserves 2D conformal invariance but breaks both spacetime translation and scale invariance and involves a chirally coupled massive scalar. The resulting MHV celestial amplitudes are completely finite (apart from the usual soft and collinear divergences and isolated poles in the sum of the weights) and take the canonical CFT form. Moreover, we show they can be simply rewritten in terms of AdS 3 -Witten contact diagrams which evaluate to the well-known D-functions, thereby forging a direct connection between flat and AdS holography.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2014

Microstructure and Strengthening Mechanisms in an Ultrafine Grained Al-Mg-Sc Alloy Produced by Powder Metallurgy

Additions of Sc to an Al-Mg matrix were investigated, paying particular attention to the influence of Al3Sc precipitates and other dispersoids, as well as grain size, on mechanical behavior. Prior studies have shown that Sc significantly increases the strength of coarse-grained Al-Mg alloys. Prompted by these findings, we hypothesized that it would be of fundamental and technological interest to study the behavior of Sc additions to an ultrafine-grained (UFG) microstructure (e.g., 100’s nm). Accordingly, we investigated the microstructural evolution and mechanical behavior of a cryomilled ultrafine grained Al-5Mg-0.4Sc (wt pct) and compared the results to those of an equivalent fine-grained material (FG) produced by powder metallurgy. Experimental materials were consolidated by hot isostatic pressing (HIP’ing) followed by extrusion or dual mode dynamic forging. Under identical processing conditions, UFG materials generate large Al3Sc precipitates with an average diameter of 154 nm and spaced approximately 1 to 3 µm apart, while precipitates in the FG materials have a diameter of 24 nm and are spaced 50 to 200 nm apart. The strengthening mechanisms are calculated for all materials and it is determined that the greatest strengthening contributions for the UFG and FG materials are Mg-O/N dispersion strengthening and precipitate strengthening, respectively.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Interrogating the Effects of Hydrogen on the Behavior of Planar Deformation Bands in Austenitic Stainless Steel

The effects of internal hydrogen on the deformation microstructures of 304L austenitic stainless steel have been characterized using electron backscattered diffraction (EBSD), transmission Kikuchi diffraction (TKD), high-resolution scanning transmission electron microscopy (HRSTEM), and nanoprobe diffraction. Samples, both thermally precharged with hydrogen and without thermal precharging, were subjected to tensile deformation of 5 and 20 pct true strain followed by multiple microscopic interrogations. Internal hydrogen produced widespread stacking faults within the as-forged initially unstrained material. While planar deformation bands developed with tensile strain in both the hydrogen-precharged and non-precharged material, the character of these bands changed with the presence of internal hydrogen. As shown by nanobeam diffraction and HRSTEM observations, in the absence of internal hydrogen, the bands were predominantly composed of twins, whereas for samples deformed in the presence of internal hydrogen, ε -martensite became more pronounced and the density of deformation bands increased. For the 20 pct strain condition, α '-martensite was observed at the intersection of ε -martensite bands in hydrogen-precharged samples, whereas in non-precharged samples α '-martensite was only observed along grain boundaries. We hypothesize that the increased prevalence of α '-martensite is a secondary effect of increased ε -martensite and deformation band density due to internal hydrogen and is not a signature of internal hydrogen itself.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Aluminothermic Reduction Process Under Nitrogen Gas Pressure for Preparing High Nitrogen Austenitic Steels

The aluminothermic reduction casting process under nitrogen gas pressure to make austenitic Cr-Mn-N (Ni-free) and Cr-N (Ni/Mn-free) high nitrogen stainless steels was investigated. Thermodynamic simulation of the redox reaction depending on process parameters was performed. As a result, the optimal ratio of aluminum to oxygen in the initial powder mixture to obtain the highest yield of metal product with minimal aluminum nitride contamination was predicted to be slightly greater than the stoichiometric ratio of 1.125. Microstructures of aluminothermic 26Cr1N and 23Cr9Mn1N steels, prepared taking into account the results of thermodynamic simulation, were investigated by X-ray diffraction, metallography, and transmission electron microscopy. The as-cast microstructure was a pseudo-pearlite (layered ferrite-nitride mixture) in 26Cr1N steel and a ferrite-austenite with signs of discontinuous austenite decomposition in 23Cr9Mn1N steel. After hot forging and subsequent water quenching from 1200 °C, the microstructure was fully austenitic in both steels. Tensile tests of quenched 23Cr9Mn1N steel showed a combination of high strength (ultimate strength of 1324 MPa) and ductility (elongation of 27 pct). The results illustrate that the aluminothermic casting process for producing high nitrogen steel is competitive with the commonly used methods, such as pressure electroslag remelting, both in terms of cost and mechanical properties of manufactured steel.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Microstructure and Mechanical Behavior of High-Entropy Alloys

High entropy alloys (HEA) have generated interest in recent years due to their unique positioning within the alloy world. By incorporating a number of elements in high proportion, usually of equal atomic percent, they have high configurational entropy, and thus, they hold the promise of interesting and useful properties such as enhanced strength and alloy stability. The present study investigates the mechanical behavior, fracture characteristics and microstructure of two singlephase FCC high-entropy alloys (HEA's) CoCrFeNi and CoCrFeNiMn with some detailed attention given to melting, homogenization and thermo-mechanical processing. Ingots approaching 8 kg in mass were made by vacuum induction melting (VIM) to avoid the extrinsic factors inherent to small scale laboratory button samples. A computationally based homogenization heat treatment was given to both alloys in order to eliminate any solidification segregation. The alloys were then fabricated in the usual way (forging, followed by hot rolling) with typical thermo-mechanical processing parameters employed. Transmission electron microscopy (TEM) was subsequently used to assess the single phase nature of the alloys prior to mechanical testing. Tensile specimens (ASTM E8) were prepared with tensile mechanical properties obtained from room temperature through 800°C. Material from the gage section of selected tensile specimens was extracted to document room and elevated temperature deformation within the HEA's. Fracture surfaces were also examined to note fracture failure modes. The tensile behavior and selected tensile properties were compared with results in the literature for similar alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Effect of Normalizing Temperature on Fracture Characteristic of Tensile and Impact Tested Creep Strength-Enhanced Ferritic P92 Steel

The high-temperature Cr-Mo creep strength-enhanced ferritic (CSEF) steels are mainly used in nuclear and thermal power plants. In the present investigation, a systematic study on fracture surface morphologies of tensile and impact tested specimens and mechanical properties of cast and forged (C&F) P92 steel was performed for various heat treatment conditions. The heat treatment was carried out in normalizing temperature range of 950-1150 °C and then tempered to a fixed tempering temperature of 760 °C. The effect of varying normalizing temperatures before and after tempering on microstructure evolution, tensile properties, Vicker’s hardness and Charpy toughness was studied. The normalizing temperature before and after tempering was having a noticeable effect on mechanical properties of as-received P92 steel. The fracture surface of impact and tensile tested samples was also studied for various normalizing temperatures with or without tempering. Fracture surface morphology was affected by the presence of secondary phase carbide particles. The fraction area of cleavage facets on the tensile fracture surface was found to be increased with an increase in the normalizing temperature. The fractured tensile specimens were characterized by transgranular ductile dimples, tear ridges and transgranular cleavage facets for various heat treatments. The fracture mode of impact tested samples was more complex. It showed both quasi-cleavage facets and ductile dimple tearing for various normalizing temperatures.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Microstructural Evolution and Mechanical Properties of Ti-22Al-25Nb (At.%) Orthorhombic Alloy with Three Typical Microstructures

Microstructural evolution, tensile and creep behavior of Ti-22Al-25Nb (at.%) orthorhombic alloy with three typical microstructures were investigated. The three typical microstructures were obtained by different solution and age treatment temperatures and analyzed by the BSE technique. The tensile strengths of the alloy at room temperature and 650 °C were investigated. The creep behaviors of the three typical microstructures were also studied at 650 °C/150 MPa for 100 h in air. The phase transformation mechanisms in creep deformation were also found. The experimental results showed that the formations of the three typical microstructures were decided by the isothermal forging and heat treatment. It was supposed that the high-temperature solution treatment might be dominant for the volume fraction and diameter of the equiaxed particles. While the double age treatment would lead to lamellar O phases. Due to grain refinement strengthening, the equiaxed microstructure presented the best tensile strength and ductility. The fully lamellar microstructure had the best creep resistance than that of other microstructures. In this paper, the phenomenon of creep-induced α{sub 2} phase decomposition was occurred during creep deformation of the equiaxed microstructure.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Deformation Mechanisms and Formability Window for As-Cast Mg-6Al-2Ca-1Sn-0.3Sr Alloy (MRI 230D)

The hot deformation characteristics of MRI 230D alloy have been evaluated in the temperature range 260-500 °C and strain rate range 0.0003-10 s{sup −1}, on the basis of processing map. The processing map exhibited two domains in the ranges: (1) 300-370 °C and 0.0003-0.001 s{sup −1} and (2) 370-480 °C and 0.0003-0.1 s{sup −1}. Dynamic recrystallization occurs in the both domains with basal slip dominating in the first domain along with climb as recovery process and second-order pyramidal slip dominating in the second with the recovery by cross-slip. In Domains (1) and (2), the apparent activation energy values estimated using the kinetic rate equation are 143 and 206 kJ/mole, respectively, the first one being close to that for lattice self-diffusion confirming climb. It is recommended that the alloy is best processed at 450 °C and strain rates less than 0.1 s{sup −1}, where non-basal slip and cross-slip occur extensively to impart excellent workability. The alloy exhibits flow instability in the form of adiabatic shear band formation and flow localization at lower temperatures and higher strain rates. Forging of a cup-shaped component was performed under various conditions, and the results validated the predictions of the processing map on the workability domains as well as the instability regimes.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Study on the Correlation Between Dynamical Behavior and Friction/Wear Mechanism Under the Effect of Grooves

In this work, the interfacial friction and wear and vibration characteristics are studied by sliding a chromium bearing steel ball (AISI 52100) over both multi-grooved and single-grooved forged steel disks (20CrMnMo) at low and high rotating speeds in order to reveal the effect mechanism of groove-textured surface on tribological behaviors. The results show that the grooves modify the contact state of the ball and the disk at the contact interface. This consequently causes variations in the normal displacement, normal force, and friction force signals. The changes in these three signals become more pronounced with increasing groove width at a low speed. The collision behavior between the ball and the groove increase the amplitude of vibration acceleration at a high speed. The test results suggest that grooves with appropriate widths could trap wear debris on the ball surface while avoiding a strong collision between the disk and the ball, resulting in an improvement in the wear states.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Improving Corrosion Resistance and Corrosive Wear Resistance of Aluminum Alloy Drill Pipe by Surface Nanocrystallization and Micro-arc Oxidation

To improve the corrosion and wear resistance performance of aluminum alloy drill pipes in geological and petroleum drilling applications, a strengthening coating was prepared on the surface of the 2618 aluminum alloy by combining treatment with ultrasonic cold forging technology (UCFT) and micro-arc oxidation (MAO). The effects of the strengthening coating on the corrosion and wear resistance of the aluminum alloy were evaluated by electrochemical and tribological tests. The results demonstrated that the corrosion and wear resistance of the aluminum alloy were improved by the UCFT and MAO technologies, especially the salt corrosion resistance. The corrosion morphology of the strengthening coating primarily included pitting, micro-cracks and NaCl attachment. In addition, the UCFT + MAO composite coating exhibited the best wear performance. The wear rate of the UCFT + MAO composite coating was lower than that of the aluminum alloy by 94%. The results provided support for this excellent surface treatment technology for the corrosion and wear resistance of aluminum alloy drill pipes, and they also present a feasible evaluation method for drill pipes.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Structural Evolution in Mechanically Alloyed and Spark Plasma Sintered Iron–0.15 wt.% MWCNT Composite

High-energy ball milling (HEBM) of mixtures of iron powder and multi-walled carbon nanotube (MWCNT) has been performed in an attempt to synthesize nano-grained steel. Even after exposure to a harsh HEBM conditions, the MWCNTs are seen to have retained their structural identity, and therefore, an MWCNT-reinforced steel matrix composite could be finally produced. Moreover, the study has revealed that the minor addition of copper leads to a significant reduction in grain size of ferrite in the so-produced steel matrix–MWCNT composite. It is also noticed that the fine grain structure of ferrite remains intact even after consolidation of the powder composite by spark plasma sintering, followed by hot forging. The micro-hardness values obtained for the composites (with/without copper) are observed as comparable with the submicron-grained steels, so far reported in the literature.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2019

Retained Austenite Attributes and Mechanical Performance of Different Compositions of TRIP Steel Alloys

The main objective of this work is to correlate the different attributes of retained austenite phase in TRIP steel structure with its mechanical properties. Three different chemical compositions were used to produce TRIP steel alloys. The first alloy contains only silicon as a carbide precipitation inhibitor; in the second alloy, silicon is partially replaced with aluminum, while in the third alloy phosphorus is added to the silicon–aluminum alloy. These compositions were proposed in order to avoid the negative effect of silicon during galvanizing. These three steel alloys were cast, homogenized, hot-forged and then subjected to intercritical annealing treatment followed by cooling and isothermal treatment in salt bath with subsequent air-cooling. Microstructural characterization, using optical microscope, SEM and XRD, along with tensile testing was carried out. Retained austenite attributes include volume fraction, carbon content, total carbon content, retained austenite transformable index and its stability coefficient against strain-induced martensite (SIM) transformation. The effect of these attributes on the mechanical properties of the studied TRIP steel alloys was evaluated using tensile test date, i.e., ultimate tensile strength (UTS), ductility, yield strength to UTS ratio, performance index and strain-hardening exponent. The variation of strain-hardening rate and strain-hardening exponent with strain was also considered. The failure behavior of the studied steel alloys was investigated using SEM on tensile-tested specimens. The results show that Si/Al-alloy has the lowest retained austenite transformable index, lowest stability coefficient against SIM transformation, highest performance index and more stable and uniform variation in strain-hardening rate and strain-hardening exponent with strain. These properties satisfy the industrial constrains of the sheets used in automotive industry relating to better mechanical properties and galvanizability.

36 MATERIALS SCIENCE↗
DOE OSTI2019

On Mechanical Properties of New Railway Wheel Steels for Desert Environments and Sand Caused Wheel Damage Mechanisms

Worn railway wheels after service in the desert were investigated by means of failure analysis, hardness measurements, tensile tests, fracture toughness tests and low-cycle fatigue (LCF) tests. The results complete both previous small-scale laboratory experiments and FEM simulations performed by the authors on widely used steels and new steel grades allowing to better understand the main damage mechanisms due to the sand. These new steel grades were developed for forged-rolled solid wheels in alternative to AAR Class B/C/D steel grades and were designed to ensure high resistance to wear and rolling contact fatigue in the presence of sand, debris or gravel on the rails. This paper covers the in-depth mechanical characterization of wheels made of the new steels. Hardness measurements, tensile tests, fracture toughness tests and LCF tests were carried out. The results are compared with AAR Class B/C/D steels showing an excellent combination of fracture toughness, cyclic yield strength and ductility.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Tailoring Microstructure and Properties of a Superelastic Ti–Ta Alloy by Incorporating Spark Plasma Sintering with Thermomechanical Processing

A powder metallurgy Ti–35 at.% Ta alloy was produced using a spark plasma sintering process. The sintered alloy exhibited Ta-rich regions at a sintering temperature of 1100 °C. Complete diffusion of elemental powders was achieved via homogenization heat treatment at 1500 °C for 12 h, but the ductility declined drastically. The brittle behavior of the homogenized sample was due to the high-oxygen content, continuous grain boundary α-phase and high-angle grain boundaries. Excellent mechanical properties were achieved when hot forging was used along with preheating the homogenized specimen at 1100 °C. The mechanisms underlying this phenomenon were suppression of the solid grain boundary α-phase, high fraction of low-angle grain boundaries and dynamic recrystallization. Tensile strength improved to the maximum value of 868 MPa. The strain recovery ratio increased to 90% in the first cycle during a cyclic loading–unloading test. Incomplete strain recovery of the first cycle was due to the presence of the martensite phase (α″).

36 MATERIALS SCIENCE↗
DOE OSTI2019

The Application of Canned Deformation to a Hard-Deformed Spray-Deposited Al-Zn-Mg-Cu Alloy

A wide variety of industrial applications require Al-Zn-Mg-Cu alloys with high strength and ductility. However, Zn-rich Al-Zn-Mg-Cu alloys prepared by rapid solidification methods usually show excellent strength but poor formability, which restricts their wide application in complex forming. In this study, we developed a new deformation method for the spray-deposited Zn-rich Al-Zn-Mg-Cu alloy to avoid crack formation and achieve isotropic properties. The microstructure evolution and crystallographic textures were analyzed and compared with the results of a normal deformation process. Crack-free forgings with the ultimate tensile strength (UTS), yield strength (YS) and elongation of 727 ± 5 MPa, 690 ± 3 MPa, 5.0 ± 0.7% along the radial direction and 735 ± 2 MPa, 693 ± 3 MPa, 6.3 ± 0.2% along the tangential direction were finally obtained. The improvement in the mechanical properties can be attributed to the larger amount of subgrains and substructures generated in the canned deformed alloy. The results of this study show excellent advantages and potential application prospects of the canned deformation to hard-deformed Al-Zn-Mg-Cu alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Primary Carbides on the Sharpness of Kitchen Knives Made of 8Cr13MoV Steel

Although there are many primary carbides in the cutting edge of knives made of high-carbon martensitic steel, the effect of primary carbides on the sharpness of knives has not been clarified. In this paper, the evolution of primary carbides during the production process of 8Cr13MoV steel was presented. The effect of size and amount of primary carbides on the sharpness of knives was studied via employing rolling forging and diffusion annealing process, respectively. Results indicated that primary carbides easily fell off from cutting edge during cutting process, which would decrease the wear resistance of knives. The refinement of primary carbides could not only improve the wear resistance of cutting edge, but also weaken the fluctuation of sharpness during the service process of knives. By decreasing the amount of primary carbides, the wear resistance of knives would increase effectively, which improved the cutting performance effectively. Reducing the amount of primary carbides and refining the primary carbides in cutting edge were both effective ways to improve the sharpness of knives.

36 MATERIALS SCIENCE↗