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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 721 records · Page 40
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

High-Temperature Properties and Microstructural Stability of the AISI H13 Hot-Work Tool Steel Processed by Selective Laser Melting

The microstructural stabilities, softening resistance, and high-temperature tensile properties of the H13 hot-work tool steel by selective laser melting (SLM) were systematically studied. A series of tempering procedures were performed on the as-SLMed specimens. Afterwards, the mechanism of softening resistance behavior was discussed based on the XRD, SEM, EBSD observations, hardness measurements, and high-temperature tensile tests. It was found that the as-SLMed H13 consisted of α-iron and γ-iron. The carbide-stabilizing elements aggregated as the cell-like substructures for the rapid solidification of the SLM process. After the softening resistance treatment, the retained austenite transformed to ferrite and carbide mixtures. The cell-like substructures dissolved slowly into the matrix when the temperature was below 550 °C. These factors increased the hardness and retarded the softening of the material. When the temperature was 600 °C, the microstructural constituents transformed to soft ferrite and globular carbides, which lead to a considerable decrease of the hardness. Due to the grain refinement, solid solution strengthening, and residual stress, the as-SLMed H13 exhibited better mechanical properties than that of the wrought counterparts.

36 MATERIALS SCIENCE↗
DOE OSTI2024

A Comprehensive Review on Finite Element Analysis of Laser Shock Peening

Laser shock peening (LSP) is a formidable cold working surface treatment that provides high-energy precision to enhance the mechanical properties of materials. This paper delves into the intricacies of the LSP process, offering insights into its methodology and the simulation thereof through the finite element method. This review critically examines various points, such as laser energy, overlapping of shots, effect of LSP on residual stress, effect of LSP on grain refinement, and algorithms for simulation extrapolated from finite element analyses conducted by researchers, shedding light on the nuanced considerations integral to this technique. As the significance of LSP continues to grow, the collective findings underscore its potential as a transformative technology for fortifying materials against mechanical stress and improving their overall performance and longevity. The discourse encapsulates the evolving landscape of the LSP, emphasizing the pivotal role played by finite element analysis in advancing our understanding and application of this innovative surface treatment.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Different Forms of Application of a Laser Surface Treatment on Fatigue Crack Growth of an AA6013-T4 Aluminum Alloy

This work analyzes the effect of surface-localized laser heating treatment on the fatigue crack growth (FCG) rate on region II of the sigmoidal da/dN × ΔK curve of an aerospace-grade AA6013-T4 aluminum alloy sheet with 1.3 mm thickness. The influence on microstructure changes is also evaluated. Aiming to improve the FCG resistance without changing the mechanical behavior of the alloy, a Yb:fiber laser beam is defocused to generate a laser spot diameter of 2 mm, using 200 W power and a laser speed of 2 mm/s. Two laser lines are applied over fatigue C(T) specimens in two different forms: on only one and on both lateral specimen surfaces. Guinier–Preston zones, dispersoids and coarse constituent particles are found on the base material. On the heat-treated material, the same precipitates and also β′ and Q′ precipitates are found. These microstructural variations due to the laser thermal cycle, together with the presence of induced compressive residual stresses, improved the fatigue behavior of the material. The FCG retardation is optimized when two laser lines were applied on both lateral surfaces of the specimen.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Inelasticity and Nanostructured Dislocation Deformation of Aluminum–Silicon Alloy with a Supermodified Eutectic Structure

Young’s modulus and the logarithmic decrement of oscillations at a frequency of ~100 kHz as well as the subgrain size and residual stresses in the strontium modified alloy of aluminum with 15 wt % silicon have been studied. The alloy was obtained with a solidification rate of 1 mm/s at the shifted eutectic point. The dependence of inelastic dislocation deformation on the applied oscillating stress has been obtained and analyzed. The effect of strontium modification on the microstrain diagram can be accounted for by transformation of the lamellar fiber structure of eutectic silicon into a superfine fiber structure.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
NASA NTRS2015

Multiscale Modeling of Ceramic Matrix Composites

Results of multiscale modeling simulations of the nonlinear response of SiC/SiC ceramic matrix composites are reported, wherein the microstructure of the ceramic matrix is captured. This micro scale architecture, which contains free Si material as well as the SiC ceramic, is responsible for residual stresses that play an important role in the subsequent thermo-mechanical behavior of the SiC/SiC composite. Using the novel Multiscale Generalized Method of Cells recursive micromechanics theory, the microstructure of the matrix, as well as the microstructure of the composite (fiber and matrix) can be captured.

ceramic matrix composites↗
DOE OSTI2019

Lead Whisker Formation in the Gold-Lead System

Metallic whiskers of pure lead (Pb) have been observed in the solder of several types of transistors. The conditions that lead to these whiskers were evaluated, including characterization of the whisker lengths and whisker density as a function of time and temperature. The potential cause and impact they would have on the reliability of electronics has been investigated. Based on these results, it is hypothesized that these whiskers may be caused by the relief of residual stresses that are created during the evolution of Au-In and/or Au-Pb intermetallic compounds or, possibly, by a decomposition of the AuPb{sub 3} phase. Due to their small size, the Pb whiskers that were observed were considered to not be a reliability concern, but similar or larger Pb whiskers could cause electrical failure in some applications.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Toward Process-Based Quality through a Fundamental Understanding of Weld Microstructural Evolution

Here, in this overview paper, the possibility of qualifying welded components by integrating software and hardware tools that are capable of describing physical processes that occur during welding is explored. The existing and emerging tools to define geometrical boundary conditions, process parameters, heat and mass transfer, solidification, solid-state transformation, plastic deformation, distortion, residual stress, and performance of welded components are reviewed. Existing challenges relevant to the fundamental understanding of complex alloying, processing environment, and transients in energy deposition are discussed with reference to microstructure evolution. Finally, approaches to address these challenges were articulated with published case studies relevant to welding and additive manufacturing.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Characteristics of Bi-metallic Interfaces Formed During Direct Energy Deposition Additive Manufacturing Processing

Various additive manufacturing processes are being evaluated to reduce the time and cost for fabrication of low volume, complex, and multifunctional assemblies. This study evaluated two direct energy deposition processes for the fabrication of large bi-metallic structures. The materials evaluated were Inconel 625 and copper alloy C18150, which are used in various high heat flux applications. Inconel was deposited onto the C18150 substrate using blown powder and wire-fed processes. Complete bonding was obtained in both processes and the resulting interfaces were evaluated using microscopy and indentation testing. Differences were observed in the interface region suggesting the kinetic energy of the blown powder process resulted in more residual stress at the interface, promoting recrystallization and enhanced diffusion. This created a broader interface in the blown powder specimens compared to a narrower mechanically mixed interface with the wire-fed process.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Improvement of Al/Steel Tungsten Inert Gas Welding–Brazing Joint by High-Energy Shot Peening

High-energy shot peening treatment was applied to improve the Al/steel tungsten inert gas welding–brazing lap joint. The mechanical properties and microstructure evolution of the joint were investigated. Results showed that the mechanical properties of weld were evidently reinforced due to microstructure transformation of joint surface layer. The grain structure in the joint surface layer was distorted and refined. Large compressive residual stress was introduced into the joint surface, and its hardness obviously increased due to strain hardening. When the peening pressure was 0.15 MPa, the tensile shear strength of the joint reached the maximum value (199.6 MPa), which was 16.5% higher than that of the as-welded joint.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Characterization of Thick Tungsten Coating on Cu Alloy Substrate Prepared by Electrodeposition

The W coating with the thickness over 1 mm was obtained by pulse electrodeposition on large CuCrZr alloy in a Na{sub 2}WO{sub 4}–WO{sub 3} molten salt. The composition of this system keeps unchanged with the duration of electrodeposition. The coating’s structure, morphology and contents were investigated by XRD, XPS and SEM. The electrodepostion tungsten coating was compact and without void. The residual stress in surface of W coating was calculated to be a compressive stress with the value of 225 MPa. The W coating comprised an inner tooth-like layer and an outer columnar layer. The bonding strength between W coating and CuCrZr susbtrate was near 60 MPa; the thermal conductivity parallel to the crystal growth direction was measured to be 150.86 W m{sup −1} K{sup −1}.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Influence of the Microstructure on Magnetic Stray Fields of Low-Carbon Steel Welds

This study examines the relationship between the magnetic mesostructure with the microstructure of low carbon steel tungsten inert gas welds. Optical microscopy revealed variation in the microstructure of the parent material, in the heat affected and fusion zones, correlating with distinctive changes in the local magnetic stray fields measured with high spatial resolution giant magneto resistance sensors. In the vicinity of the heat affected zone high residual stresses were found using neutron diffraction. Notably, the gradients of von Mises stress and triaxial magnetic stray field modulus follow the same tendency transverse to the weld. In contrast, micro-X-ray fluorescence characterization indicated that local changes in element composition had no independent effect on magnetic stray fields.

42 ENGINEERING↗
DOE OSTI2018

Formability, Microstructure and Mechanical Properties of Flow-Formed 17-4 PH Stainless Steel

The subject of the research that has been conducted in this paper was to analyze precipitation-hardened martensitic stainless steel 17-4 PH after flow forming with four different strains and subsequent standard heat treatment. Four cylinders were obtained with a 16, 30, 48 and 68% reduction in thickness, respectively. The samples were analyzed in terms of their mechanical properties and microstructural changes before and after the heat treatment. The results showed that a higher strain resulted in an overall higher strength (up to 1200 MPa UTS) and refinement of the structure, although at a cost of the elongation. High deformation influenced the precipitation process, and the ratio of the grain boundaries significantly increased. Nonetheless, comparing the obtained results with other similar research, it seems that the formation of nano-precipitates of Cu is the key-strengthening mechanism. Strain hardening contributes to an increase in the strength of the steel, although the effect decreases after heat treatment. The relatively small values of residual stress in the steel, especially after the heat treatment, confirmed these claims. Overall, flow forming allowed high deformations of the 17-4 PH steel to be obtained although it did not significantly change the mechanical properties of the material due to the dominant precipitation hardening mechanism.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Interfacial characteristics of P91 steel - Inconel 740H bimetallic structure fabricated using wire-arc additive manufacturing

Although bimetallic structures can offer unique solutions to engineering problems with varying functionality, joining two dissimilar alloys using additive manufacturing involves challenges such as cracking and segregation. In this work, bimetallic structures of Inconel 740H superalloy and P91 steel are processed using wire-arc additive manufacturing (WAAM) for the first time. P91 steel is directly deposited over 740H with a cooling time of 20 minutes in between the two depositions. During microstructure characterization, a large gradient zone with coarse grains spanning for ~2200 μm is observed. Moreover, the microhardness of the gradient zone is the least in comparison with the P91 and 740H deposits. No deleterious phase formation is found; however, intergranular cracks are observed along the gradient zone. In order to deduce the reason for cracking, non-equilibrium solidification simulations are performed for the mixed compositions of P91 and 740H in the gradient zone. Here, the reasons for crack formation in the gradient zone are the sudden change in the volumetric coefficient of thermal expansion due to the formation of MC carbides as well as the development of local strains from the thermal residual stresses. Therefore, altering the deposition sequence and introducing gradient layers with mixed composition between the P91 and 740H deposits will be beneficial in achieving defect-free builds. Through the integration of experiments and simulation, this work gains valuable insights into the processability of dissimilar alloy manufacturing using the WAAM technique.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2018

Environmental Cracking and Irradiation Resistant Stainless Steels by Additive Manufacturing

Metal additive manufacturing (AM), or metal 3D printing is an emergent advanced manufacturing method that can create near net shape geometries directly from computer models. This technology can provide the capability to rapidly fabricate complex parts that may be required to enhance the integrity of reactor internals components. Such opportunities may be observed during a plant refueling outage and AM parts can be rapidly custom designed, manufactured and deployed within the outage interval. Additive manufacturing of stainless steel (SS) components can add business benefits on fast delivery on repair hardware, installation tooling, new design prototypes tests, etc. For the nuclear industry, the supply chain is always an issue for reactor service. AM can provide through-life supply chain (40-60 years) for high-value low-volume components. In the meantime, the capability of generating complex geometries and functional gradient materials will improve the performance, reduce the overall component cost, plant asset management cost and increase the plant reliability by the improvement in materials performance in nuclear environments. While extensive work has been conducted regarding additively manufacturing of austenitic SS parts, most efforts focused only on basic attributes such as porosity, residual stress, basic tensile properties, along with components yield and process monitoring. Little work has been done to define and evaluate the material requirements for nuclear applications. Technical gaps exist, which limit this technology adoption in the nuclear industry, which includes high manufacturing cost, unknown risks, limited nuclear related data, lack of specification and qualification methods, and no prior business experience. The main objective of this program was to generate research data to address all these technical gaps and establish a commercial practice to use AM technology in the nuclear power industry. The detailed objectives are listed as follows: (1) Evaluate nuclear related properties of AM 316L SS, including microstructure, tensile properties, impact toughness, stress corrosion cracking (SCC), corrosion fatigue (CF), irradiation effects, and irradiation assisted stress corrosion cracking (IASCC). (2) Understand the correlations among laser processing, heat treatment, microstructure and SCC/irradiation properties; (3) Optimize and improve the manufacturing process to achieve enhanced nuclear application properties; (4) Fabricate, evaluate, qualify and test a prototype reactor component to demonstrate the commercial viability and cost benefit; (5) Create regulatory approval path and commercialization plans for the production of a commercial reactor component.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2018

Magnetic Barkhausen noise characterization of two pipeline steels with unknown history

Highlights: • The hardness, microstructure, texture and MBN of two pipeline steels were analyzed. • The angular MBN results revealed possible manufacturing histories of the two pipelines. • The MBN is closely related to the processing history, microstructure and stress state. • The use of MBN technique can help address the integrity issues in the pipeline industry. Steel samples cut from two line pipes with unknown processing history were analyzed using magnetic Barkhausen noise (MBN), electron backscatter diffraction (EBSD) and Vickers hardness techniques on the pipe surface and on sections through the wall thickness. The results show that the MBN responses vary significantly not only between the two pipe steels, but also among different thickness layers of each steel. Both steels show considerable variations in MBN at different locations on the surfaces. For one steel, the surface MBN illustrates an inverse linear relationship with respect to the hardness, while the other does not depict such a relation since the variation in hardness at different locations is very small. Across the thickness, the microstructure (phase and grain size) of both steels is quite similar, but the texture shows significant differences. Again, there is a large difference in hardness across the thickness for one steel, while the other only shows very small variation in hardness across the thickness. The variations in average MBN across the wall thickness for both steels are quite large. Angular MBN measurements on the sectioned samples revealed significant discrepancies in the magnetic anisotropy in the two steels. Based on the analysis of the angular MBN data with respect to the single and dual easy axis models, one pipe can be determined to have been manufactured through a seam welding process, while the other may have been formed by spiral welding. Due to the residual stresses in the steel samples, the effect of the crystallographic texture on the anisotropy in MBN response has essentially been suppressed.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Effect of Plate Hardening Behavior on the Deformation of Stainless Steel Metal Bellows

Tensile tests of original plate samples from three types of stainless steel metal bellows were performed at room temperature. The constitutive equations for the three hardening curves were obtained and fitted. The analysis results of the microstructure and fracture morphology of the tensile specimens show that the grain size of the plate with a high logarithmic–exponential hardening rate is uneven and the dimple of the shear fracture is elongated into an ellipse. By contrast, the grain size of the plate with a relatively low linear hardening rate is even and the dimple of the fracture is uniformly equiaxial. Finite element simulations of the hydraulic bulging and repeated limit bending deformation of the metal bellows of the three types of materials were also conducted. The repeated limit bending deformation process was tested experimentally. Although the effect of the hardening exponent on the residual stress of the metal bellows after hydraulic bulging is minimal, this exponent considerably influences the repeated limit bending deformation of the metal bellows after subsequent use. The trough hardening phenomenon is serious in the repeated limit bending process. Moreover, when the hardening exponent of the original plate is high, the resistance to bending fracture at the trough area is poor.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Friction Stir Welding of Dissimilar Al/Al and Al/Non-Al Alloys: A Review

Friction stir welding is a solid-state welding technique that has many advantages over traditional fusion welding, and has been widely adopted in the aerospace and automotive industries. This article reviews research developments in friction stir welding of dissimilar alloys systems, including combinations of aluminum alloys with Mg alloys, Cu, and steel. Microstructural evolution, hardness, tensile and fatigue properties, residual stresses, and corrosion behavior of dissimilar welds will be reported. The effects of processing parameters such as tool rotation and traverse speeds, tool position, material position, and tool geometry on the weld quality are also presented. Discussions on future research directions in friction stir welding will also be provided in the context of existing literature and future high-integrity applications.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Corrosion and Fatigue Behavior of High-Strength Steel Treated with a Zn-Alloy Thermo-diffusion Coating

High and low cycle fatigue tests were conducted on high-strength steel using four-point bending. The materials tested were ASTM A723 steel in the as-machined condition, grit-blasted condition, MIL-DTL-16232 heavy manganese phosphate-coated condition, and ASTM A1059 Zn-alloy thermo-diffusion coated (Zn-TDC). The ASTM A723 steel base material exhibits a yield strength of ~1000 MPa. The effects of the surface treatments versus uncoated steel were examined. The fatigue life of the Zn-TDC specimens was generally reduced on as-coated specimens versus uncoated or phosphate-coated specimens. Several mechanisms are examined including the role of compressive residual stress relief with the Zn-TDC process as well as fatigue crack initiation from the hardened Zn-Fe alloy surface layer produced in the gas-metal reaction. Additionally, the effects of corrosion pitting on the fatigue life of coated specimens are explored as the Zn-TDC specimens exhibit significantly improved corrosion resistance over phosphate-coated and oiled specimens.

36 MATERIALS SCIENCE↗