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Role of geometric dynamic recrystallization in nanocrystalline alloys
Nanocrystalline and near-nano-grained metals are plagued with an overall lack of ductility and formability. This is in part due to their inability to support the dislocation mechanisms or undergo the same types of transformations that conventional coarse-grained metals access in order to increase their workability. Therefore, despite their advanced properties such as high strength, the manufacturing of such fine-grained metals, which exposes them to multi-axial states of stress in operations such as rolling, drawing, extrusion, forging, and bending, has not been possible. In this work, we address this limitation and highlight an important aspect of geometric dynamic recrystallization (GDRX) in nanocrystalline materials as a way to improve manufacturability. In particular, using two different alloy compositions and two different processing techniques, this study points to the fact that if nanocrystalline or near nano metals can be truly stabilized, they can repeatedly undergo the same types of processes that conventional coarse-grained metals endure, increasing both their formability and hence manufacturability. The results reveal that due to a large number of initial high-angle grain boundaries and large applied compressive strains, GDRX is activated in the absence of any discontinuous dynamic recrystallization (DDRX) or continuous dynamic recrystallization (CDRX). This is a unique aspect of stabilized nanocrystalline materials, as traditionally fine-grained metals are not microstructurally stable enough to accommodate such an event.
Materials for Advanced Ultra-Supercritical (A-USC) Steam Turbines --- A-USC Component Demonstration
The U.S. Advanced Ultra-Supercritical (A-USC) Consortium was formed in 2001 as a government/industry program, sponsored by the U.S. Department of Energy (DOE) and the Ohio Coal Development Office (OCDO) and cost shared by industrial and not-for-profit partners. The purpose of the consortium was to advance the state of the art for power generation by evaluating and developing materials that allow the use of advanced steam cycles in coal-based power plants. These advanced cycles, with steam temperatures up to 1400°F (760°C), can increase the efficiency of coal-fired boilers from an average of 35% (current U.S. fleet) to more than 45% higher heating value (HHV) (>49% lower heating value [LHV]). The increase in a plant’s efficiency is limited unless new materials able to withstand these higher operating temperatures and pressures are identified and approved for use. The A-USC Consortium identified these needed materials during earlier phases of the program. It developed the welding and joining techniques along with manufacturing processes for casting and wrought products made from these new high-nickel alloys. It subjected these materials to extensive laboratory and steam loop testing. It then obtained ASME code approval for their use in U.S. boiler systems. The program’s successes leave this last remaining activity (ComTest Phase 2) that the U.S. utility industry has recommended to be accomplished prior to commercialization. The focus of the activity is the evaluation and demonstration of commercial readiness for “full scale” components to be made from these nickel-based alloy materials and provided by a U.S. domestic supply chain that is new to working with these alloys. According to studies completed by the Electric Power Research Institute (EPRI), the cost of an A-USC plant is approximately 20% higher than a non-A-USC plant because of its use of nickel-based alloys needed for the high temperature operating conditions. However, CO 2 reductions of approximately 30% from the current fleet average provide a strong incentive for its consideration. The actual costs and perceived value for CO 2 abatement will determine whether new or retrofitted plants are undertaken, although decisions to build A-USC plants in India would indicate its economic feasibility while also being part of a global carbon emissions strategy. The work by the A-USC Consortium, prior to the start of the ComTest project, has included lab scale and pilot scale materials testing, both in air and oxy-combustion. This testing has included air-cooled and steam-cooled “loops” that were installed into existing operating utility boilers to gain exposure of these materials to realistic conditions of high temperature and corrosion caused by the constituents in the coal ash. The A-USC Consortium also gained ASME Code approval of the Inconel 740 material, has cast and extruded the largest high nickel precipitation hardened alloys, and developed unique welding techniques to avoid problems identified by the competing European program. However, as valuable as these material test loops and accomplishments have been for obtaining information, their scale is below that required to minimize the risk associated for a U.S. utility to build a multibillion-dollar A-USC power plant. To reduce the final identified risk barrier to full-scale commercialization of these advanced materials and systems, the A-USC Consortium (guided by a utility industry advisory committee) has identified the key areas of the technology they desire to see as being capable of full-scale manufacturing and/or fabrication from an identified, capable U.S. domestic supplier base. A significant amount of work was accomplished during Phase 1 to identity the components, as well as the component size, that would be manufactured from advanced alloys such as Inconel 740H or Haynes 282 alloys. Pathways to supply these components for ComTest have been identified, as well as any further development that would be required. The Phase 2 effort used Phase 1 findings for designing these key full-scale components for A-USC boilers and turbines to include large castings; extrusions, forgings, fabrication of water walls and steam loops with headers from advanced materials, raw material (such as pipe extrusion billets) are at the commercial readiness level to permit advancement to a demonstration project. The Phase 2 work scope was addressed by a diverse team, including government, industry, and not-for-profit partners. The work scope under Phase 2 addressed fabrication of components identified as being outside of the proven capabilities of the existing supply chain, including the following: Steam turbine rotor forging and Haynes 282 nozzle carrier casting Superheater and reheater header and tube assemblies Large-diameter pipe extrusions and forgings Test valve articles to support ASME Code approval. In addition, key fabrication steps were completed, including boiler weld overlays and simulated field repairs. Throughout, extensive inspection and quality assurance testing of the components were performed. The team worked to advance ASME Code approval for key components and processes. Although much of the focus of ComTest Phase 2 was the high-temperature nickel-based alloy materials, a broader range of materials were incorporated, which would be representative of the materials used in full-scale A-USC power plant applications and have cross-cutting applicability on other high-temperature power generation options, such as advanced nuclear, supercritical CO 2 cycles, and central solar receivers. This report that has been submitted is organized in the following manner: Section 1 contains an Executive Summary. Section 2 discusses the ComTest project background and organization. Section 3 discusses project management and reporting. Section 4 discusses the procurement of nickel-based alloy and other A-USC materials and components. Section 5 discusses the fabrication of procurement of nickel-based alloy and other A-USC materials and components. Section 6 discusses the fabrication of cast nickel-based A-USC steam turbine components. Section 7 discusses the fabrication of forged nickel-based A-USC steam turbine piping and steam pipe components. Section 8 discusses the qualification of pressure relieve valves (PRVs) for A-USC power plants. Section 9 discusses proposed plans for future evaluation of A-USC components. Section 10 contains the summary and conclusion.
A deformation-processed Al-matrix/Ca-nanofilamentary composite with low density, high strength, and high conductivity
Light, strong materials with high conductivity are desired for many applications such as power transmission conductors, fly-by-wire systems, and downhole power feeds. However, it is difficult to obtain both high strength and high conductivity simultaneously in a material. In this study, an Al/Ca (20 vol%) nanofilamentary metal-metal composite was produced by powder metallurgy and severe plastic deformation. Fine Ca metal powders (~200 µm) were produced by centrifugal atomization, mixed with pure Al powder, and deformed by warm extrusion, swaging, and wire drawing to a true strain of 12.9. The Ca powder particles became fine Ca nanofilaments that reinforce the composite substantially by interface strengthening. The conductivity of the composite is slightly lower than the rule-of-mixtures prediction due to minor quantities of impurity inclusions. As a result, the elevated temperature performance of this composite was also evaluated by differential scanning calorimetry and resistivity measurements.
Hydrogen-isotope evidence for extrusion mechanisms of the Mount St Helens lava dome
Hydrogen isotope analyses were used to determine water content and deuterium content for 18 samples of the Mount St Helens dome dacite in an attempt to identify the triggering mechanisms for periodic dome-building eruptions of lava. These isotope data, the first ever collected from an active lava dome, suggest a steady-state process of magma evolution combining crystallization-induced volatile production in the chamber with three different degassing mechanisms: closed-system volatile loss in the magma chamber, open-system volatile release during ascent, and kinetically controlled degassing upon eruption at the surface. The data suggest the future dome-building eruptions may require a new influx of volatile-rich magma into the chamber.
A systematic multicriteria-based approach to support product portfolio selection in microalgae biorefineries
Here this work proposes and applies a sequential approach of objective methods to aid the decision-making process for the deployment of microalgae biorefineries. The strategy combines Multicriteria Decision Analysis (MCDA) and weight assignment methods to simultaneously consider technical, economic, and environmental criteria to (1) outrank the best bioproduct options from different biomass fractions present in microalgae biomass at different ratios (namely carbohydrates, lipids, and protein) and (2) define the most suitable biorefining pathways associated with specific pairings of microalgae strains and cultivation conditions. The first part of the assessment identified succinic acid, acrylic acid, and citric acid as the top-ranked bioproducts from carbohydrates, polyurethane from lipids, and thermoplastic extrusion co-feed from protein. The second step of the analysis determined that, when production of a hydrocarbon fuel is desired, the compositional profile of a strain is paramount in defining the biorefining setup that should be pursued. In summary, microalgae lipids should be sent to the production of hydrocarbon fuels if the ratio between neutral lipids and fermentable carbohydrates is higher than roughly 1, with carbohydrates and protein being converted to the higher-value products noted above. Finally, this result was corroborated through process simulations, which indicated superior economic and environmental metrics when strains are paired with suitable conversion pathways identified through MCDA based on their compositional profiles. The outcomes of this work provide clear, objective, guidelines for establishing the best biorefining approach for a large suite of biochemical compositions as a screening method prior to employing detailed process simulations alongside rigorous techno-economic and life-cycle assessments.
Hot Deformation and Processing Maps of B{sub 4}C/6061Al Nanocomposites Fabricated by Spark Plasma Sintering
We developed 3 vol.% B{sub 4}C/6061Al nanocomposites by spark plasma sintering. We then characterized their flow and hot deformation behaviors using isothermal compression tests at deformation temperatures of 673-823 K and strain rates of 0.001-1 s{sup −1}. Results indicated that their steady flow characteristic can be described by the Zener–Hollomon parameter (Z) as a hyperbolic-sine function of flow stress. Based on pinning effect from B{sub 4}C nanoparticles, the estimated activation energy was calculated to be 274.80 kJ/mol. At the unstable deformation condition (723 K/1 s{sup −1}) with high Z, flow localization appeared; the main softening mechanisms involved are dynamic recovery and dynamic recrystallization (DRX). At the stable deformation condition (823 K/0.001 s{sup −1}) with low Z, adequate DRX occurred. Based on the processing map and microstructure evolution, the optimum hot working conditions for B{sub 4}C/6061Al nanocomposites were determined to be a deformation temperature of 773-823 K and a strain rate of 0.001-0.003 s{sup −1}. These working conditions were verified by a hot extrusion test.
Lunar mare domes - Classification and modes of origin
In this paper, lunar mare domes (LMDs) are classified according to morphologic and morphometric (primarily diameter) characteristics, and consideration is given to their origin and role in lunar surface processes. In general, they occur either as low, flat, circular structures with convex shapes, slopes less than about 5 deg, and display summit craters, or as irregular structures often adjacent to highland regions and rarely containing summit craters. It is found that LMDs originate through extrusion of lavas through vents to produce low lava shields, or through flooding and draping of preexisting topography to produce kipukas and irregular domes. Smooth, vent-related mare domes range from about 3-17 km in diameter and up to several hundred meters in elevation; they are similar in morphology to small terrestrial lava shields.
Geochemical anomalies on the eastern limb and farside of the moon
A variety of orbital geochemistry and photogeologic data was used to investigate major geochemical anomalies on the east limb and farside of the moon and to determine the processes responsible for their formation. These anomalies are located in the following regions: (1) near Langemak crater, (2) Mare Marginis, (3) Balmer crater, (4) terrain north of Taruntius crater, and (5) Van de Graaff. It was concluded that these anomalies are related to episodes of extrusive igneous activity which produced deposits with a variety of ages and compositions. Some of the associated volcanic deposits exhibit albedos and surface morphologies similar to those of the nearside maria, while others are now thinly covered by highland debris and are commonly represented by light plains units which exhibit clusters of dark-haloed craters. Little evidence was found for a genuine episode of highland volcanism (e.g., Apollo 15 KREEP basalt, highland basalt, etc.). The existence of intermediate basalts on the eastern limb and farside supports previous suggestions that KREEP-like volcanism was not limited to a small area of the lunar nearside. Eastern limb and farside volcanic activity has been more extensive in both space and time and has produced a greater variety of compositions than has previously been thought. Since thinly covered basaltic units can exert a strong influence on regional surface chemistry as determined from orbit, caution is urged in interpreting the surface compositions of highland terrains which exhibit a high density of dark-haloed impact craters.
Flow in the Proximity of the Pin-Tool in Friction Stir Welding and Its Relation to Weld Homogeneity
In the Friction Stir Welding (FSW) process a rotating pin inserted into a seam literally stirs the metal from each side of the seam together. It is proposed that the flow in the vicinity of the pin-tool comprises a primary rapid shear over a cylindrical envelope covering the pin-tool and a relatively slow secondary flow taking the form of a ring vortex about the tool circumference. This model is consistent with a plastic characterization of metal flow, where discontinuities in shear flow are allowed but not viscous effects. It is consistent with experiments employing several different kinds of tracer: atomic markers, shot, and wire. If a rotating disc with angular velocity w is superposed on a translating continuum with linear velocity omega, the trajectories of tracer points become circular arcs centered upon a point displaced laterally a distance v/omega from the center of rotation of the disc in the direction of the advancing side of the disc. In the present model a stream of metal approaching the tool (taken as the coordinate system of observation) is sheared at the slip surface, rapidly rotated around the tool, sheared again on the opposite side of the tool, and deposited in the wake of the tool. Local shearing rates are high, comparable to metal cutting in this model. The flow patterns in the vicinity of the pin-tool determine the level of homogenization and dispersal of contaminants that occurs in the FSW process. The approaching metal streams enfold one another as they are rotated around the tool. Neglecting mixing they return to the same lateral position in the wake of the tool preserving lateral tracer positions as if the metal had flowed past the tool like an extrusion instead of being rotated around it. (The seam is, however, obliterated.) The metal stream of thickness approximately that of the tool diameter D is wiped past the tool at elevated temperatures drawn out to a thickness of v/2(omega) in the wiping zone. Mixing distances in the wiping zone are multiplied in the unfolded metal. Inhomogeneities on a smaller scale than the mixing length are obliterated, but structure on a larger scale may be transmitted to the wake of a FSW weld.
Direct ink writing of aqueous-based Gadolinium (III) oxide slurries
Gadolinium (III) oxide (gadolinia, Gd 2 O 3 ) has recently been identified as an intriguing material for applications in the medical, solid oxide fuel cell, and nuclear industries. This interest drives the need for developing and understanding manufacturing techniques that can produce dense Gd 2 O 3 structures. Direct ink writing (DIW), an extrusion-based additive manufacturing method, has also garnered interest because of its capability to produce dense ceramic parts with increased complexity in an economical manner. In this study, DIW was explored as a manufacturing technique for Gd 2 O 3 . Experiments were performed to develop Gd 2 O 3 bearing inks capable of being processed via DIW. Ink solids loading and sintering temperatures were varied to assess their impact on the final density and microstructure. Optimum sintering conditions are proposed and were experimentally verified at a dwell temperature of 1500°C. Gd 2 O 3 samples were successfully manufactured using DIW, achieving densities greater than 96 % of the theoretical density.
Native Ion Mobility Mass Spectrometry: When Gas-Phase Ion Structures Depend on the Electrospray Charging Process
Ion mobility spectrometry (IMS) has become popular to characterize biomolecule folding. Numerous studies have shown that proteins that are folded in solution remain folded in the gas phase, whereas proteins that are unfolded in solution adopt more extended conformations in the gas phase. Here, we discuss how general this tenet is. We studied single-stranded DNAs (human telomeric cytosine-rich sequences with CCCTAA repeats), which fold into an intercalated motif (i-motif) structure in a pH-dependent manner, thanks to the formation of C–H{sup +}–C base pairs. As i-motif formation is favored at low ionic strength, we could investigate the ESI-IMS-MS behavior of i-motif structures at pH ~ 5.5 over a wide range of ammonium acetate concentrations (15 to 100 mM). The control experiments consisted of either the same sequence at pH ~ 7.5, wherein the sequence is unfolded, or sequence variants that cannot form i-motifs (CTCTAA repeats). The surprising results came from the control experiments. We found that the ionic strength of the solution had a greater effect on the compactness of the gas-phase structures than the solution folding state. This means that electrosprayed ions keep a memory of the charging process, which is influenced by the electrolyte concentration. We discuss these results in light of the analyte partitioning between the droplet interior and the droplet surface, which in turn influences the probability of being ionized via a charged residue-type pathway or a chain extrusion-type pathway. .
Material extrusion additive manufacturing of wood pulp-reinforced epoxy composites
Direct ink writing (DIW) is an extrusion-based form of 3D-printing that has gained popularity over the last decade. DIW uses thixotropic fluid extrusion to form a particular shape. In order to form stable structures, the rheology of the paste is important to allow for extrusion from the syringe, stability of the growing print, and prevention of unwanted seeping flow during jog moves. In this work, we use wood pulp as a bio-based filler that can provide shear thinning properties to the ink, which produces a stable ink for DIW processing. Additionally, the filler imparts improved mechanical and thermal performance compared to neat resin. The wood pulp provided the shear thinning behavior necessary for DIW printing, and pulp loadings greater than 6 wt%, provided sufficient yield stress so that the composite could self-support during printing. Nanoclay was utilized to further improve ink rheology and appearance to enable larger scale printing. Overall, this work showed successful DIW of an epoxy resin with a sustainable filler improving its stiffness and thermal properties and provides an avenue for further development of bio-based inks for DIW towards various applications.
Precision Aluminum Forming Final Report CRADA No. TC-0187-91
Lawrence Livermore National Laboratory (LLNL), Sandia National Laboratories (SNL), and ALCOA Technical Center joined together to advance the state of the art in computation analysis of aluminum forming processes. LLNL and SNL developed numerical modeling tools that incorporated material models and interface models provided by ALCOA. The two DOE laboratories and ALCOA jointly participated in the validation of the software package by modeling a set of benchmark forming data in the areas of rolling, forging, and extrusion. These forming benchmarks were produced by ALCOA. The software package was delivered to ALCOA and is being used in forming research.
Recent developments in materials and detectors for the infrared; Proceedings of the Meeting, Cannes, France, November 25, 26, 1985
The present conference on advancements in IR-sensitive materials and detector technologies employing them gives attention to thermal detectors, focal plane array processing detectors, novel detector designs, general properties of IR optics materials, and preparation methods for such materials. Specific topics encompass the fabrication of InSb MIS structures prepared by photochemical vapor deposition, IR heterodyne detectors employing cadmium mercury telluride, low microphony pyroelectric arrays, IR detection based on minority carrier extrusion, longwave reststrahl in IR crystals, and molecular beam techniques for optical thin film fabrication.
Mechanical Alloying and Powder Forging of 18%Cr Oxide Dispersion-Strengthened Steel Produced Using Elemental Powders
Oxide dispersion-strengthened (ODS) ferritic steels are potential materials for cladding tubes in fast breeder fission reactors. These are mostly prepared by mechanical alloying of yttria powder with pre-alloyed powders. Using elemental powders offers flexibility in the choice of alloy compositions. Here we report mechanical alloying of Fe-18Cr-2W-0.2Ti-0.35Y{sub 2}O{sub 3} (compositions in wt.%) ODS steel using elemental powders of Fe, Cr, W and Ti with yttria powder. After 5 h of milling, no significant changes in particle size and crystallite size were observed. Powders milled for 5 and 7 h were consolidated through powder forging route. The optimum milling time for mechanical alloying could be determined only after evaluating the forgings. It is difficult to achieve recrystallization in ODS alloys. The forging process parameters were optimized to achieve a dense alloy with a fine recrystallized microstructure. Factors leading to recrystallization are discussed. It is shown that recrystallization in ODS steels is more likely to occur during forging as compared to extrusion/rolling. The powder forging route offers several advantages over the conventional extrusion or HIP routes.
Mechanical alloying, characterization and consolidation of Ti-Al-Ni alloys
Mechanical alloying is being investigated as a processing route for the production of aluminide intermetallics. This program involves powder production and characterization, consolidation and thermal treatments and determination of microstructure-property relationships. An attritor mill is being used to produce powder in lots up to 1000 grams and the processing parameters are being systematically varied to establish the optimum milling conditions. The mill is being instrumented to generate data related to the processing to provide a basis for theoretical modeling. Powder is being characterized using thermal analysis, optical and electron microscopy and X-ray diffraction. Particle size distributions and powder density are being determined. Consolidation of the powder is being approached in several different ways including, cold isostatic pressing, sintering, extrusion and hot pressing. The results of the program so far will be presented and future directions discussed.
Elevated temperature cracking of RSP aluminum alloy 8009 - Characterization of the environmental influence
Degradation of the material properties of the Al alloy is examined to determine the effects of moist air and predissolved hydrogen on elevated-temperature fatigue and fracture resistance. Experiments are conducted at 175 C in both moist air and high vacuum with as-processed specimens and specimens that are vacuum-heat-treated. Fracture mechanics characterizations are made for initiation and propagation fracture toughnesses during rising load, fatigue-crack propagation kinetics, and sustained-load crack-growth rates. Time-dependent embrittlement at intermediate temperatures is identified in both plate and extrusion samples of the Al-Fe-Si-V alloy 8009. Intermediate temperature cracking is found to be the same for each case in both vacuum and moist air, and the vacuum heat treatment does not significantly affect the results.