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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 OSTI2018

Quantifying High-Performance Material Microstructure Using Nanomechanical Tools with Visual and Frequency Analysis

High-performance materials like ballistic fibers have remarkable mechanical properties owing to specific patterns of organization ranging from the molecular scale, to the micro scale and macro scale. Understanding these strategies for material organization is critical to improving the mechanical properties of these high-performance materials. In this work, atomic force microscopy (AFM) was used to detect changes in material composition at an extremely high resolution with transverse-stiffness scanning. New methods for direct quantification of material morphology were developed, and applied as an example to these AFM scans, although these methods can be applied to any spatially-resolved scans. These techniques were used to delineate between subtle morphological differences in commercial ultra-high-molecular-weight polyethylene (UHMWPE) fibers that have different processing conditions and mechanical properties as well as quantify morphology in commercial Kevlar®, a high-performance material with an entirely different organization strategy. Both frequency analysis and visual processing methods were used to systematically quantify the microstructure of the fiber samples in this study. These techniques are the first step in establishing structure-property relationships that can be used to inform synthesis and processing techniques to achieve desired morphologies, and thus superior mechanical performance.

Sandoz-Rosado, Emil↗
NASA NTRSDate not supplied

Multiscale Modeling of Reconstructed Tricalcium Silicate using NASA Multiscale Analysis Tool

To study microstructure characteristics of cementitious materials hydrated in space; previously, cement binder formations were processed under microgravity conditions and was further compared against ground-based experiments. For accurate estimation of process-structure-property linkage, particularly on samples hydrated in the microgravity environment, it is desired to have a high-fidelity volumetric representation of the microstructure. However, owing to small sample size and high porosity of the space-returned samples, conventional experimental characterization techniques are not viable. Hence, a deep learning-based reconstruction algorithm was employed to obtain high fidelity 3D volumes from sparse high resolution 2D Scanning Electron Microscopy (SEM) images, as inputs to micromechanics-based modeling. This machine learning-based reconstruction methodology validated against low-order statistical descriptors, captured the microstructural topology of both sample types (ground, 1g and microgravity, μg). Due to the lack of gravity, hydration products of the samples processed in space differed from those processed-on ground. Such AI-generated virtual samples were analyzed in a multiscale recursive micromechanics approach using the NASA Multiscale Analysis Tool (NASMAT). Here, we present a methodology to rapidly integrate and evaluate these AI-generated volumes in NASMAT. The synthesized microstructural volumes are directly employed as Representative Volume Elements (RVEs) to preserve the fidelity (1 pixel = 0.54 m). Invariably, analysis of such largescale problems (5123 voxels) requires huge amount of computational resources. By taking advantage of the NASMAT architecture, we also focused on systematic multiscale integration of these AI-reconstructed virtual volumes to reduce the computational demands. In this work, this methodology is demonstrated on the ground-based, 1g samples. The estimated stiffness value of 15.90 GPa is comparable to experimentally obtained modulus of hydrated tricalcium silicate sample. The workflow presented here paves the way for utilizing the NASMAT tool to perform multiscale analyses of other multi-phase material systems using either 3D virtual datasets synthesized using AI or obtained via micro-CT.

Machine Learning↗
NASA NTRS1986

Microstructure/mechanical property relationships for various thermal treatments of Al-Cu-Mg-X PM aluminum alloys

The thermal response and aging behavior of three 2XXX-series powder metallurgy aluminum alloys have been investigated, using Rockwell B hardness measurements, optical and electron microscopy, and energy-dispersive chemical analysis, in order to correlate microstructure with measured mechanical properties. Results of the thermal response study indicated that an increased solution heat treatment temperature was effective in resolutionizing large primary constituents in the alloy bearing more copper but had no apparent effect on the microconstituents of the other two. Aging studies conducted at room temperature and at 120, 150, and 180 C for times ranging up to 60 days indicated that classic aging response curves, as determined by hardness measurements, occurred at lower aging temperatures than were previously studied for these alloys, as well as at lower aging temperatures than are commonly used for ingot metallurgy alloys of similar compositions. Microstructural examination and fracture surface analysis of peak-aged tension specimens indicated that the highest tensile strengths are associated with extremely fine and homogeneous distributions of theta-prime or S-prime phases combined with low levels of both large constituent particles and dispersoids. Examination of the results suggest that refined solution heat treatments and lower aging temperatures may be necessary to achieve optimum mechanical properties for these 2XXX series alloys.

Blackburn, L. B.↗
DOE OSTI2019

Influence of Austempering Temperature and Time on the Microstructure and Mechanical Properties of Ductile Iron Weldment Using Developed Coated Electrode

Sound welded joints of ductile iron were first made by developing coated electrodes as well as weld procedure. The weldments were then austenitized at 900 °C for 2-h holding time followed by austempering at 300 and 350 °C for three different holding times (1.5, 2 and 2.5 h) at each austempering temperature. The influence of austempering temperature and time on the microstructural and mechanical properties was studied. Microstructural characterization, phase analysis, microhardness and mechanical properties were performed to understand the effect of austempering heat treatment on microstructure, austempering kinetics and mechanical properties of welded joints. In spite of significant variation in microstructures among all the three zones of DI weldment before austempering, the response of both weld metal and HAZ to austempering heat treatment similar to a base metal was noted. However, a significant variation in matrix structures (bainitic ferrite, retained austenite) as well as graphite nodules among the three zones was observed with changing the austempering temperature and holding time. Also, 100% joint efficiency of the welded joints was achieved at both 300 and 350 °C for 2-h holding time. Hardness and charpy impact toughness mostly depended on the volume fraction of retained austenite and carbon content. Based on the results of tensile and charpy impact testing, 350 °C and 2-h holding time could be considered as an optimum austempering condition for ADI weldment.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Clustering Algorithm for AM Parts using GSH and EDT with Autoencoder

SAND2025-10103O The Clustering Algorithm for AM Parts Using GSH and (EDT With Autoencoder is a software tool. It uses a clustering algorithm for additive manufacturing (AM) parts using generalized spherical harmonics (GSH) and Euclidean distance transform (EDT) with an autoencoder to quantify material microstructure. The tool offers improved sensitivity to microstructural changes compared to traditional approaches. The tool integrates multiple microstructural properties, such as grain morphology, crystallographic orientation, and material phase information, to provide a comprehensive analysis of material microstructures. Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525.

Rodgers, Theron [Sandia National Lab. (SNL-CA), Li↗
NASA NTRS1990

Characterization of the tensile and microstructural properties of an aluminum metal matrix composite

This study examines a powder metallurgy aluminum alloy in the unreinforced state and with a discontinuous reinforcement of 15 v/o or 30 v/o SiC whisker or 15 v/o SiC particulate. The materials were extruded and then hot-rolled to three plate thicknesses of 6.35, 3.18 and 1.8 mm and were investigated in the as-fabricated and peak aged conditions. The influence of mechanical working on the reinforcement morphology and distribution were examined. A comparison of the mechanical properties was made and the elastic moduli of the reinforced materials were predicted using a micromechanics model. Fractography of tensile specimens revealed that the fracture process was dominated by the presence of microstructural inhomogeneities which were related to both the matrix alloy and to the reinforcement type. An analysis of these microstructural features and a description of the micromechanics model are presented in the paper.

Birt, M. J.↗
DOE OSTI2018

Effect of the hydration temperature on the pore structure of cement paste: Experimental investigation and micromechanical modelling

The hydration temperature has a considerable effect on the microstructure of cement paste. The microstructural changes with increasing curing temperature result in a significant decrease of cement mechanical properties. The present work aims at studying these phenomena via micromechanical modelling, based on an experimental characterization of cement microstructure. The pore structure of a class G oil-well cement paste (American Petroleum Institute classification) hydrated at different temperatures, between 7 °C and 90 °C is characterized. Then, the influence of the microstructure variations on the elastic properties of the hardened paste is explored through micromechanical modelling. A previous analysis of the microstructure enabled determining the volume fractions of different phases of a class G cement paste hydrated under different temperatures [1]. A multiscale self-consistent homogenization model is used based on these results to simulate the variations of the mechanical properties with hydration temperature. The results are compared with macro-scale elastic properties obtained from uniaxial compression tests. It is shown that the increasing capillary porosity with elevating hydration temperature, is not sufficient to fully explain this drop of elastic properties. The latter originates mainly from the decrease of the elastic properties of the foam composed of the porous C-S-H intermixed with capillary pores. The pore structure analysis coupled with the micromechanical modelling permitted a back-analysis of the intrinsic porosities of high density and low density C-S-H showing an almost constant LD intrinsic porosity and a significantly decreasing HD intrinsic porosity.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Stochastic nonlinear analysis of unidirectional fiber composites using image-based microstructural uncertainty quantification

Here, we present a data-driven nonlinear uncertainty quantification and propagation framework to study the microstructure-induced stochastic performance of unidirectional (UD) carbon fiber reinforced polymer (CFRP) composites. The proposed approach integrates (1) microscopic image characterization, (2) stochastic microstructure reconstruction, and (3) efficient multiscale finite element simulations enabled by self-consistent clustering (SCA) analysis. To model the complex microstructural variability, the proposed UQ methods take the non-Gaussian uncertainty sources into account through a distribution-free sampling approach leveraging nonparametric and asymptotic statistical tools. A hierarchical conditional sampling strategy enables the simultaneous sampling of multiple sources of uncertainties. Our approach provides insights into the impact of microstructural variabilities, which are shown to have an increasing impact on the nonlinear responses of UD CFRP parts under progressive compression loading and ultimately on the failure rate over time. We discover that before CFRP parts start to fail, a characteristic time period emerges with distinctive uncertainty distributions specific to the microstructure variability and the probability of failure. Identifying the failure time period is crucial to the reliability prediction, which is an essential component of CFRP design.

36 MATERIALS SCIENCE↗
DOE OSTI2020

XtalCAMP: a comprehensive program for the analysis and visualization of scanning Laue X-ray micro-/nanodiffraction data

XtalCAMP is a software package based on the MATLAB platform, which is suitable for, but not limited to, the analysis and visualization of scanning Laue X-ray micro-/nanodiffraction data. The main objective of the software is to provide complementary functionalities to the Laue indexing software packages used at several synchrotron beamlines. Here, the graphical user interfaces allow the easy analysis of characteristic microstructure features, including real-time intensity mapping for a quick examination of phase, grain and defect distribution, 2D color-coded mapping of microstructural properties from the output of other Laue indexing software, crystal orientation visualization, grain boundary characterization based on orientation/misorientation calculation, principal strain/stress analysis, and strain ellipsoid representation, as well as a series of additional toolkits. As an example, XtalCAMP is applied to the microstructural investigation of a solution-heat-treated Ni-based superalloy manufactured using a laser 3D-printing technique, and a deformed natural quartzite from Val Bregaglia in the Central Alps.

36 MATERIALS SCIENCE↗
DOE OSTI2019

NEUTRON-IRRADIATION–INDUCED DAMAGE ASSESSMENT IN CONCRETE USING COMBINED PHASE CHARACTERIZATION AND NONLINEAR FAST FOURIER TRANSFORM SIMULATION

Understanding irradiation effects in concrete cavities of light water reactors is critical to the long-term operation (60+ years) of US nuclear power plants. Susceptibility of concrete to neutron irradiation greatly varies as a function of its constituents: coarse aggregates, sand, and hardened cement paste (hcp). In particular, higher irradiation–susceptibility of aggregates was found to be a direct function of radiation-induced volumetric expansion (RIVE), or the propensity of aggregates to swell as a function of mineral contents, structures and textures. Irradiation-induced amorphization is accompanied by significant swelling, especially in silicates. For example, the maximum volumetric expansions of quartz and feldspars have been shown to be as large as ≈ 18% and ≈ 8%, respectively, while the change of density in calcite remains rather low (≈ 0.3–0.5%). High swelling is associated with a high number of covalent bonds (Si–O) and a high degree of polymerization of [SiO4] tetrahedrons. Differential RIVEs between rock-forming minerals cause high stresses and may potentially develop cracking within the aggregates at the interface between aggregates and the hcp and within the hcp. Modeling neutron-irradiation effects in concrete requires addressing the problem at a scale that captures both the details of the aggregates’ mineralogy and texture, which is <~ 100 μm, and the representative size of concrete, which is ~ 10 cm. This requires high-resolution, large mapping capabilities. To this end, the US Department of Energy (DOE) Light Water Reactor Sustainability (LWRS) Program developed an original tool suite called Microstructure Oriented Scientific Analysis of Irradiated Concrete (MOSAIC) in which Nonlinear 2D-fast Fourier transform (FFT) techniques are employed to model mechanical or irradiation-induced cracking of high-resolution complex microstructures derived from combined mapping techniques, including micro x-ray fluorescence (m-XRF), energy-dispersive x-ray spectroscopy (EDS), electron backscatter diffraction (EBSD), ellipsometry, and scanning electron microscopy (SEM). Irradiated mineral properties are derived from the Irradiated Minerals, Aggregate and Concrete (IMAC) database, which includes available relevant literature data. Rigorous coupled damage-creep simulations are obtained through sequential linear analysis. Illustrations of actual accelerated irradiation-damage propagation in a complex microstructures are presented herein.

Le Pape, Yann↗
NASA NTRS2006

Burst Testing and Analysis of Superalloy Disks With a Dual Grain Microstructure

Elastic-plastic finite element analyses of room temperature burst tests on four superalloy disks were conducted and reported in this paper. Two alloys, Rene 104 (General Electric Aircraft Engines) and Alloy 10 (Honeywell Engines & Systems), were studied. For both alloys an advanced dual microstructure disk, fine grain bore and coarse grain rim, were analyzed and compared with conventional disks with uniform microstructures, coarse grain for Rene 104 and fine grain for Alloy 10. The analysis and experimental data were in good agreement up to burst. At burst, the analysis underestimated the speed and growth of the Rene 104 disks, but overestimated the speed and growth of the Alloy 10 disks. Fractography revealed that the Alloy 10 disks displayed significant surface microcracking and coalescence in comparison to Rene 104 disks. This phenomenon may help explain the differences between the Alloy 10 disks and the Rene 104 disks, as well as the observed deviations between analytical and experimental data at burst.

Gayda, John↗
NASA NTRS2020

An Algorithm for Characterization of Fiber Aggregation in Composite Microstructures

Composite structures are susceptible to localized flaws, or variability, that drive global failure. To capture this variance, a multiscale model needs to be introduced that not only accurately represents the statistical nature of the composite microstructure but is also efficient. At the microscale, fiber aggregation creates local stress concentrations, where failure is likely to occur sooner than expected. A method of rapid microstructure generation, in conjunction with cluster characterization, is examined to develop accurate reproductions of 2D composite cross-sections. Parameterization of shape and size of fiber clusters is used to characterize representative volume elements. The discrete element method is used to generate pseudo-microstructures. The clustering parameters from the pseudo- and actual microstructure arrangements (obtained from micrographs) can be compared to determine the validity of the representative volume element generated with the discrete element method. Results show a promising approach to evaluating randomness of fiber distributions and how to accurately recreate microstructures for strength analysis.

Carbon fiber↗
DOE OSTI2014

Metallographic screening of grain boundary engineered type 304 austenitic stainless steel

An electrochemical etching method for the identification of grain boundary engineered type 304 austenitic stainless steel microstructures is described. The method can be applied for rapid microstructure screening to complement electron backscatter diffraction analysis. A threshold parameter to identify grain boundary engineered microstructure is proposed, and the application of metallographic etching for characterising the degree of grain boundary engineering discussed. - Highlights: • As-received (annealed) and grain boundary engineered microstructures were compared. • Electro-chemical polarisation in nitric acid solutions was carried out. • A metallographic screening method has been developed. • The screening method complements EBSD analysis for microstructure identification.

36 MATERIALS SCIENCE↗
DOE OSTI2014

On the importance of FIB-SEM specific segmentation algorithms for porous media

A new algorithmic approach to segmentation of highly porous three dimensional image data gained by focused ion beam tomography is described which extends the key-principle of local threshold backpropagation described in Salzer et al. (2012). The technique of focused ion beam tomography has shown to be capable of imaging the microstructure of functional materials. In order to perform a quantitative analysis on the corresponding microstructure a segmentation task needs to be performed. However, algorithmic segmentation of images obtained with focused ion beam tomography is a challenging problem for highly porous materials if filling the pore phase, e.g. with epoxy resin, is difficult. The gray intensities of individual voxels are not sufficient to determine the phase represented by them and usual thresholding methods are not applicable. We thus propose a new approach to segmentation that pays respect to the specifics of the imaging process of focused ion beam tomography. As an application of our approach, the segmentation of three dimensional images for a cathode material used in polymer electrolyte membrane fuel cells is discussed. We show that our approach preserves significantly more of the original nanostructure than a thresholding approach. - Highlights: • We describe a new approach to the segmentation of FIB-SEM images of porous media. • The first and last occurrences of structures are detected by analysing the z-profiles. • The algorithm is validated by comparing it to a manual segmentation. • The new approach shows significantly less artifacts than a thresholding approach. • A structural analysis also shows improved results for the obtained microstructure.

36 MATERIALS SCIENCE↗
NASA NTRS2005

Assessment of NASA Dual Microstructure Heat Treatment Method Utilizing Ladis SuperCooler(trademark) Cooling Technology

The intent of this investigation was to demonstrate the NASA DMHT method with a tailored Ladish SuperCool(Trademark) cooling method on a Rolls-Royce AE2100, stage 3 disk shape. One disk each of two alloys, LSHR and ME3, were successfully converted as shown by macrostructure. DMHT heating time selection and cooling rate was aided by finite element modeling analysis. Residual stresses were also predicted and reported. Detailed microstructural analysis was performed by NASA and included in this report. Mechanical property characterization, also planned by NASA, is incomplete at this time and not part of this report.

Lemsky, Joe↗
DOE OSTI2019

Effect of Chemical Composition on the Microstructure and Properties of the Ag-Ga-Ge Alloys

This study presents a comparison of thermodynamically calculated phase compositions of Ag-Ga-Ge alloys at fixed temperatures with phase analysis results of alloys annealed at respective temperatures. Three isothermal sections of the Ag-Ga-Ge system at 25, 100 and 300 °C have been extrapolated using optimized thermodynamic parameters from the literature. An experimental analysis of the microstructure was carried out using optical microscopy, scanning electron microscopy and energy-dispersive spectrometry. Results obtained by x-ray powder diffraction methods (identified phases and lattice parameters) were compared with the results of the predicted phase equilibria. Good overall agreement between experimental and calculated values was obtained. The Brinell hardness and electrical conductivity of selected alloys were measured and obtained results were analyzed with respect to their overall compositions and phase constituents.

36 MATERIALS SCIENCE↗