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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 667 records · Page 37
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Thermomechanical Behavior of Biocompatible Austenitic Stainless Steels during Simulated Torsion Tests

The thermomechanical behavior and the microstructural evolution during the hot deformation are important aspects of metal alloys during hot forging and rolling processes. Here, the correlation between dynamically recrystallized grain size (d{sub DRX}), steady-state stress (σ{sub ss}) and Zener–Hollomon (Z) parameter is investigated according to the Universal Derby–Ashby relationship. Specimens of a UNS S 31673 and a UNS S 31675 steels, used in the manufacture of orthopedic implants, were subjected to continuous isothermal torsion tests. A strain of 3.0 and strain rates of 0.01, 0.1, 1.0 and 10 s{sup −1} at temperatures of 1000, 1100 and 1200 °C, were employed. The results showed that the competition between the hardening and dynamic softening (i.e., recovery and recrystallization) mechanisms, as depicted by the flow curves, agreed with the Derby relation. This observation is also a consequence of the variation in the stacking fault energy (SFE) with the applied strain. Additionally, the influence of the hot deformation parameters on the shape of the curves and the grain refinement is governed by the balance between these thermally activated mechanisms.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Microstructural Characterization and Simulation of High Temperature Inelastic Deformation and Fracture of Al-Li 2070

A combined experimental and simulation investigation is carried out to characterize the high temperature deformation behavior of a recently developed Al-Li alloy, AA2070, over a temperature range including typical forging temperatures. Focus is placed on providing explanations for the temperature-dependent plastic and fracture behavior observed for this material using macroscale tensile tests, microscale imaging and analysis, and physics-based micromechanical modeling. It is shown that AA2070 experiences non-monotonic elongation to failure with a rise in temperature. Detailed fractography and microstructural analysis, including dynamic recrystallization analysis, provide insight into this interesting and practically useful behavior. In addition, a validated crystal plasticity model is called upon to explain the unique texture observed in the necked region of the ductile tensile specimen. The insights provided by this investigation will allow improved design of high temperature forming operations for AA2070 and similar alloys which can extend the application of third generation Al-Li alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Microstructure and Mechanical Behavior of Heat-Treated and Thermomechanically Processed TA15 Ti Alloy Composites

For TA15 Ti alloy, which has been widely used to form key load-bearing components in aeronautic and space fields, particular performances and corresponding microstructures are demanded due to various service environments. By applying single-phase field heat treatment, single-phase + two-phase field heat treatments, forging (α + β phase zone) combined with high-temperature aging and dual heat treatment, four types of microstructures, namely the fully lamellar microstructure, basket weave microstructure, two-phase composite microstructure and tri-modal microstructure, were obtained, respectively. And after conducting mechanical property tests for these microstructures, it was found that enhancing the lamellar thickness in the fully lamellar microstructures, reducing the content of equiaxed α phase to about 20% or increasing the content of lamellar phase in the two-phase composite microstructures and controlling the content of equiaxed α phase within 20% in the tri-modal microstructure were beneficial for performance improving. In addition, two-phase and three-phase composite microstructures possessed excellent comprehensive mechanical properties, and fully lamellar microstructures had the highest fracture toughness.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Long-Term Creep Behavior of a CoCrFeNi Medium-Entropy Alloy

We report that current research shows that high-entropy alloys (HEAs) can offer superior oxidation resistance compared to more traditional austenitic stainless steels with equivalent tensile mechanical performance. While many reports have been published on creep of CoCrFeNiMn, few focus on the CoCrFeNi family of low to medium entropy alloys. In this manuscript, uniaxial tensile creep test results for more than 46,000 accumulated hours are presented on the equiatomic CoCrFeNi alloy. The alloy was manufactured at NETL using a vacuum induction melt solidification approach with a computationally designed homogenization cycle. After completing the homogenization cycle, the ingot was first hot forged and then hot rolled into 10 mm thick plate, a product form that is relevant to many industries. Creep tests were performed in the temperature range of 600-650 °C using applied stresses from 120 to 189 MPa. This study builds upon previous results on the CoCrFeNiMn family of high-entropy alloys and offers a modicum of clarification about performance compared to small button melts by using ASTM standard test procedures and mechanical test specimens. The apparent creep activation energy and creep stress exponent were similar to those for CoCrFe medium-entropy and CoCrFeNiMn high-entropy alloys. The post-test creep microstructure showed some Cr segregation, which has also been noted for other CoCrFe alloys. The CoCrFeNi alloy also presents a double minimum or two minimum creep rate phenomena.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Temperature and Material Flow Prediction in Friction-Stir Spot Welding of Advanced High-Strength Steel

Friction-stir spot welding (FSSW) has been shown to be capable of joining advanced high-strength steel, with its flexibility in controlling the heat of welding and the resulting microstructure of the joint. This makes FSSW a potential alternative to resistance spot welding if tool life is sufficiently high, and if machine spindle loads are sufficiently low that the process can be implemented on an industrial robot. Robots for spot welding can typically sustain vertical loads of about 8 kN, but FSSW at tool speeds of less than 3000 rpm cause loads that are too high, in the range of 11–14 kN. Therefore, in the current work, tool speeds of 5000 rpm were employed to generate heat more quickly and to reduce welding loads to acceptable levels. Si3N4 tools were used for the welding experiments on 1.2-mm DP 980 steel. The FSSW process was modeled with a finite element approach using the Forge* software. An updated Lagrangian scheme with explicit time integration was employed to predict the flow of the sheet material, subjected to boundary conditions of a rotating tool and a fixed backing plate. Material flow was calculated from a velocity field that is two-dimensional, but heat generated by friction was computed by a novel approach, where the rotational velocity component imparted to the sheet by the tool surface was included in the thermal boundary conditions. An isotropic, viscoplastic Norton-Hoff law was used to compute the material flow stress as a function of strain, strain rate, and temperature. The model predicted welding temperatures to within percent, and the position of the joint interface to within 10 percent, of the experimental results.

Miles, Michael↗
DOE OSTI2015

Thermal Management in Friction-Stir Welding of Precipitation-Hardening Aluminum Alloys

Process design and implementation in FSW is mostly dependent on empirical information gathered through experience. Basic science of friction stir welding and processing can only be complete when fundamental interrelationships between process control parameters and response variables and resulting weld microstructure and properties are established to a reasonable extent. It is known that primary process control parameters like tool rotation and translation rate and forge axis force have complicated and interactive relationships to the process response variables such as peak temperature, time at temperature etc. Of primary influence to the other process response parameters are temperature and its gradient at the deformation and heat affected zones. Through review of pertinent works in the literature and some experimental results from boundary condition work performed in precipitation hardening aluminum alloys this paper will partially elucidate the nature and effects of temperature transients caused by variation of thermal boundaries in Friction Stir Welding.

Friction Stir Welding↗
DOE OSTI2022

Bettye Washington Greene: An Industrial Chemist and Inventor Who Lit a Path for Innovation

American civil rights pioneer John Lewis once wrote: “You are a light. You are the light. Never let anyone— any person or any force—dampen, dim or diminish your light.” At a time when the civil rights movement was shedding light on inequalities for African Americans, Dr. Bettye Washington Greene (March 20, 1935 – June 16, 1995) was forging a path that would light the way–figuratively and literally—for generations to come. She was one of the few African American women to earn a Ph.D. in chemistry in the 1960s, an era marked by the passing of the Voting Rights Act of 1965. Washington Greene’s doctoral thesis evaluated light-scattering methods to determine the size of particles, which influences molecular effectiveness, activity, and stability. The fundamental knowledge she provided critically aided the pharmaceutical, catalyst and cosmetics industries [1]. Following her doctoral defense, Bettye went on to become the first African American female employed in a scientific research role at the Dow Chemical Company, where her innovations were awarded three patents.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

A quality-agnostic combinatoric cost estimation model for large-format directed energy deposition metal additive manufacturing

Directed energy deposition (DED) additive manufacturing (AM) processes are amenable to synergistic combination into multi-process AM systems due to similar requirements for automation and energy sources. This work analyzes the economic performance of such DED AM systems from a quality-agnostic combinatoric standpoint with a model that calculates lowest-cost system combinations based on part geometry and process performance metrics. Common DED AM systems research focuses on a single process and does not consider the process, system, and application in the context of all possible system combinations (e.g., the combined set of process selection(s), motion system(s), and process hardware), leading to limited applicability of the resulting DED AM systems to cost-sensitive components such as those found in energy generation applications. The model developed herein incorporates the capital, material, and energy costs associated with DED AM system combinations into a predictive tool for estimating part and system cost, the output of which is intended to guide deployment of finite research and development resources towards DED AM system combinations with the lowest costs and greatest likelihood of economic impact. The DED AM systems identified by this framework may enable domestic production of the large conventionally cast and forged components necessary for energy generation.

Shanafield, Alexandra [ORNL]↗
DOE OSTI2016

High-entropy Al 0.3 CoCrFeNi alloy fibers with high tensile strength and ductility at ambient and cryogenic temperatures

High-entropy alloys (HEAs) are multi-component systems based on novel alloy composition designs with entropy maximization. They feature an array of unique mechanical properties when compared with traditional alloys. In this study, HEA fibers with diameters ranging from 1 to 3.15 mm in diameter, with the composition of Al 0.3 CoCrFeNi (atomic percent, at.%), were successfully fabricated by hot-drawing, followed by microstructural characterization using scanning-electron microscopy (SEM) and transmission-electron microscopy (TEM). The compositional variations within and between fibers were determined using energy-dispersive X-ray spectroscopy in TEM along with atomic-probe tomography (APT). These analyses revealed a homogeneous face-centered cubic (FCC) structure in the as-cast material, while post processing (e.g., forging and wire drawing) produced nanosized B2 particles in an FCC matrix. Electron back-scatter diffraction (EBSD) was used to determine the evolution of the texture and grain boundary character after processing of the fibers. The tensile strength and plasticity of the fibers were determined at both 298 K (1207 MPa/7.8%) and 77 K (1600 MPa/17.5%). Detailed TEM analyses revealed that the improvement of mechanical properties at 77 K (i.e. increased strength and ductility) is due to a change in deformation mechanisms from the planar slip of dislocations to nano-twinning. Such properties could be beneficial for cryogenic applications.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Uncertainty quantification of microstructural properties due to variability in measured pole figures

Experimental pole figures are an important input for microstructure homogenization models. In this paper, we derive an exact analytical formulation to quantify the uncertainties in homogenized properties due to uncertainty in the experimentally measured pole figures. The pole figures are acquired from a set of Ti-7Al alloy samples. These samples were obtained from the same process: by compressing a beta forged ingot at room temperature followed by annealing. The samples were taken from different regions of the original ingot, and this created variability in the resulting pole figures. The joint multivariate probability distributions of the computed orientation distribution function (ODF) is then found using the method of characteristic functions based on a Gaussian model of the pole figures. Engineering properties such as elastic modulus can be obtained by volume averaging over the ODF. We also show that uncertainty in elastic properties can be analytically obtained using direct transformation of random variables in the homogenization approach.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Enhanced high-temperature tensile property by gradient twin structure of duplex high-Nb-containing TiAl alloy

A pre-deformation process was employed for a TiAl alloy via high-temperature torsion, in which the stability of the constituent phases was tailored, resulting in enhanced hardening capability and ductility via a gradient microstructure. A sample with a pre-torsion of 360° exhibited a yield strength of 475 MPa and an ultimate tensile strength of 592 MPa, with a tensile ductility of 47% at 850 °C. The tensile properties were significantly enhanced compared with the as-forged sample, which exhibited values of 395 MPa, 494 MPa, and 4.6%, respectively. The physical mechanisms for the significant enhancement of the mechanical property of the TiAl alloys were studied in-depth via of transmission electron microscopy, electron-backscattered diffraction, and high-energy X-ray diffraction techniques. The high strength is mainly attributed to the twin structure formed during torsion, while high fracture elongation correlates to the recrystallization of the γ phase at twin-twin sections and the load partitioning regulated by a hierarchical microstructure. When the tensile micro-strains along the loading direction and transverse direction in the γ phase of the pre-deformed TiAl alloy, a higher mechanical performance was obtained. Moreover, the fracture mode of the pre-torsional tensile sample is a combination of pores and cleavage facets which resulted from the microstructure after torsion. Finally, the gradient twin structure approach in this study provides a strategy for developing TiAl alloys with exceptionally high-temperature tensile property, and the results of the micromechanical behavior-microstructure-property relationship may improve the understanding of the plastic deformation of TiAl alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Electroslag additive manufacturing: A pathway for high throughput near net shape production

Electroslag Additive Manufacturing (ESAM), a new high-throughput additive manufacturing (AM) method that combines Electroslag Strip Cladding (ESC) and wire arc AM (WAAM) is introduced. This combination enables the high deposition rate of ESC (more than 20 kg/h with a 60 mm strip electrode) to benefit from the precise geometric control of WAAM. As a precursor to ESAM, the ESC process is investigated in an AM context independently by evaluating both direct and staggered bead-stacking strategies and analyzing the microstructural and mechanical properties of each. This is followed by an ESAM demonstration producing an annular geometry by pairing ESC with gas tungsten arc welding (GTAW), wherein GTAW is utilized to construct annular walls that are subsequently infilled via ESC. The microstructure and mechanical properties of ESC-only AM are compared with that of the ESAM method and it is shown that printed integral retaining walls do not impact the resulting mechanical properties of ESAM. Furthermore, results indicate that ESAM-produced Alloy 625 parts exhibit tensile properties on par with cast counterparts, supporting the method’s scalability to components exceeding one metric ton, and possibly making ESAM a viable future manufacturing approach for competitive production of large-scale components currently manufactured by casting and forging.

Additive manufacturing↗
DOE OSTI2026

Future foundries: A convergent manufacturing platform

This article introduces the Future Foundries platform developed at Oak Ridge National Laboratory, a first-generation research system designed to demonstrate convergent manufacturing. Convergent manufacturing brings together additive, subtractive, and transformative processes in a digitally interconnected environment to enable end-to-end production workflows. By linking traditionally discrete steps, convergent platforms accelerate production, improve repeatability, and support high-mix, low-volume manufacturing. The Future Foundries platform exemplifies this vision in practice by combining four modular, vendor-agnostic process cells that include robotic WAAM, induction heating, optical metrology, and machining, coordinated through an automated pallet handler and a ROS 2-based digital thread. This architecture provides the flexibility and scalability needed for agile production in small and medium-sized manufacturing enterprises and for field deployable manufacturing. Two case studies illustrate the platform’s capabilities. The first presents an integrated workflow for fabricating, transforming, and repairing critical replacement components, showing how consolidated thermal, additive, inspection, and machining operations reduce manual part handling and streamline process flow. The second case study highlights coordinated multi-part production enabled by automated pallet logistics and multi-cell scheduling. Together, these examples showcase convergent manufacturing as a practical and scalable strategy for strengthening domestic casting and forging capacity, improving supply-chain resilience, and enabling rapid, adaptable production of mission-critical components.

Convergent manufacturing↗
DOE OSTI2021

The future low-temperature geochemical data-scape as envisioned by the U.S. geochemical community

Data sharing benefits the researcher, the scientific community, and the public by allowing the impact of data to be generalized beyond one project and by making science more transparent. However, many scientific communities have not developed protocols or standards for publishing, citing, and versioning datasets. One community that lags in data management is that of low-temperature geochemistry (LTG). This paper resulted from an initiative from 2018 through 2020 to convene LTG and data scientists in the U.S. to strategize future management of LTG data. Through webinars, a workshop, a preprint, a townhall, and a community survey, the group of U.S. scientists discussed the landscape of data management for LTG – the data-scape. Currently this data-scape includes a “street bazaar” of data repositories. This was deemed appropriate in the same way that LTG scientists publish articles in many journals. The variety of data repositories and journals reflect that LTG scientists target many different scientific questions, produce data with extremely different structures and volumes, and utilize copious and complex metadata. Nonetheless, the group agreed that publication of LTG science must be accompanied by sharing of data in publicly accessible repositories, and, for sample-based data, registration of samples with globally unique persistent identifiers. LTG scientists should use certified data repositories that are either highly structured databases designed for specialized types of data, or unstructured generalized data systems. Recognizing the need for tools to enable search and cross-referencing across the proliferating data repositories, the group proposed that the overall data informatics paradigm in LTG should shift from “build data repository, data will come” to “publish data online, cybertools will find”. Funding agencies could also provide portals for LTG scientists to register funded projects and datasets, and forge approaches that cross national boundaries. Finally, the needed transformation of the LTG data culture requires emphasis in student education on science and management of data.

58 GEOSCIENCES↗
DOE OSTI2018

A new era for electron bifurcation

Electron bifurcation, or the coupling of exergonic and endergonic oxidation-reduction reactions, was discovered by Peter Mitchell and provides an elegant mechanism to rationalize and understand the logic that underpins the Q cycle of the respiratory chain. Thought to be a unique reaction of respiratory complex III for nearly 40 years, about a decade ago Wolfgang Buckel and Rudolf Thauer discovered that flavin-based electron bifurcation is also an important component of anaerobic microbial metabolism. Their discovery spawned a surge of research activity, providing a basis to understand flavin-based bifurcation, forging fundamental parallels with Mitchell's Q cycle and leading to the proposal of metal-based bifurcating enzymes. New insights into the mechanism of electron bifurcation provide a foundation to establish the unifying principles and essential elements of this fascinating biochemical phenomenon.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Simulations of crack extensions in arc-shaped tension specimens of uncharged and hydrogen-charged 21-6-9 austenitic stainless steels using cohesive zone modeling with varying cohesive parameters

Crack extensions in uncharged and hydrogen-charged side-grooved A(T) specimens of conventionally forged 21-6-9 austenitic stainless steels are simulated using the cohesive zone modeling approach. Two-dimensional plane strain finite element analyses with fixed cohesive parameters are first conducted to fit the experimental load-displacement curves. Similar analyses using varying cohesive parameters as functions of the crack extension are then conducted to fit the experimental load-crack extension and crack extension-displacement curves. The computational results with varying cohesive parameters can fit very well the experimental data. The computational results also indicate that the average cohesive energy for the hydrogen-charged A(T) specimen is lower than that for the uncharged A(T) specimen.

42 ENGINEERING↗
DOE OSTI2016

Cryo-quenched Fe-Ni-Cr alloy single crystals: A new decorative steel

In this paper, a decorative steel is described that is formed by a process that is unlike that of the fabrication methods utilized in making the original Damascus steels over 2000 years ago. The decorative aspect of the steel arises from a three-dimensional surface pattern that results from cryogenically quenching polished austenitic alloy single crystals into the martensitic phase that is present below 190 K. No forging operations are involved – the mechanism is entirely based on the metallurgical phase properties of the ternary alloy. The symmetry of the decorative pattern is determined and controlled by the crystallographic orientation and symmetry of the 70%Fe,15%Ni,15%Cr alloy single crystals. Finally, in addition to using “cuts” made along principal crystallographic surface directions, an effectively infinite number of other random-orientation “cuts” can be utilized to produce decorative patterns where each pattern is unique after the austenitic-to-martensitic phase transformation.

36 MATERIALS SCIENCE↗