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At least 757 records · Page 42
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Schmid factor crack propagation and tracking crystallographic texture markers of microstructural condition in direct energy deposition additive manufacturing of Ti-6Al-4V

Metallic additive manufacturing (AM) provides a customizable and tailorable manufacturing process for new engineering designs and technologies. The greatest challenge currently facing metallic AM is maintaining control of microstructural evolution during solidification and any solid state phase transformations during the build process. Ti-6Al-4V has been extensively surveyed in this regard, with the potential solid state and solidification microstructures explored at length. In this study, we evaluate the applicability of previously determined crystallo- graphic markers of microstructural condition observed in electron beam melting powder bed fusion (PBF-EB) builds of Ti-6Al-4V in a directed energy deposition (DED) build process. The aim of this effort is to elucidate whether or not these specific crystallographic textures are useful tools for indicating microstructural conditions in AM variants beyond PBF-EB. Parent β-Ti grain size was determined to be directly related to α-Ti textures in the DED build process, and the solid state microstructural condition could be inferred from the intensity of specific α-Ti orientations. Qualitative trends on the as-solidified β-Ti grain size were also determined to be related to the presence of a fiber texture, and proposed as a marker for as-solidified grain size in any cubic metal melted by AM. Analysis of the DED Ti-6Al-4V build also demonstrated a near complete fracture of the build volume, suspected to originate from accumulated thermal stresses in the solid state. Crack propagation was found to only appreciably occur in regions of slow cooling with large α +β colonies. Schmid factors for the basal and prismatic α-Ti systems explained the observed crack pathway, including slower bifurcation in colonies with lower Schmid factors of both slip systems. Colony morphologies and localized equiaxed β-Ti solidification were also found to originate from build pauses during production and uneven heating of the build edges during deposition. Tailoring of DED Ti-6Al-4V microstructures with the insight gained here is proposed, along with cautionary insight on preventing unplanned build pauses to maintain an informed and controlled thermal environment for microstructural control.

36 MATERIALS SCIENCE↗
DOE OSTI2025

X-ray Micro-Computed Tomography for Structural Analysis of All-Solid-State Battery at Pouch Cell Level

Characterizing the microstructure of all-solid-state batteries (ASSBs) during fabrication and operation is vital for their advancement, particularly as scaling to pouch cell levels introduces challenges in probing large-scale microstructural evolution. This work highlights the potential of synchrotron X-ray micro-computed tomography (sXCT) as a nondestructive, rapid (<30 min), and high-resolution technique for visualizing and quantifying key microstructural features, including overhang, porosity, contact loss, active surface area, and tortuosity, in all-solid-state pouch cells. The large field of view (up to millimeters) of sXCT enables detailed analysis at an industry-relevant scale, bridging the gap between laboratory research and commercial applications. Furthermore, integrating realistic sXCT-derived 3D models into multiphysics simulations could provide insights into chemo-mechanical degradation, particularly at the edges of the pouch cells, offering a pathway for designing robust, high-performance ASSBs. This perspective establishes sXCT as an indispensable tool for advancing both the understanding and the engineering of next-generation energy storage systems.

25 ENERGY STORAGE↗
DOE OSTI2022

Accumulative Roll Bonding of Alloy 2205 Duplex Steel and the Accompanying Impacts on Microstructure, Texture, and Mechanical Properties

The mechanical and microstructural evolution of Alloy 2205 during severe plastic deformation is examined in this study. A combination of accumulative roll bonding (ARB) and cold rolling results in the successful formation of a nanograined dual-phase microstructure of austenite and ferrite with some transformed martensite. Severe deformation to cumulative reductions of 80.5, 92.5, 95, and 97 pct were performed. Microscopy indicates that grain dimensions in the sheet normal direction is less than 100 nm for reductions ≥ 92.5 pct. Shear banding is observed at reductions ≥ 95 pct while twinning is only observed at reductions < 92.5 pct. Neutron diffraction measurements indicated the presence of martensite for reductions ≥ 95 pct at ~ 8 pct volume fraction. Taken in conjunction, it appears that during initial ARB processing, both slip and twinning are active plastic mechanisms. As twinning becomes exhausted, martensitic transformation, slip, and intermittent shear banding account for the active plasticity mechanisms. Material hardness saturates at 92.5 pct reduction, with a maximum hardness of 45 HRC. Sub-sized tensile testing confirms this approximate hardness with measurements indicating a UTS of ~ 1440 MPa. Texture analysis of crystal orientation distributions in the plate normal direction suggest an approximate Kurdjumov–Sachs orientation relationship at all reductions above 80 pct indicating stability of the orientation relationship at high strains. The intragranular structure develops a fine scale sub-grain content with increasing deformation, resulting in a continual evolution of texture up to and including 97 pct reduction. The final structure presents strong components of Goss and rotated cube texture in both the austenite and ferrite. In this body of work we aim to compare ARB of an industrially relevant FCC/BCC system (Alloy 2205) to historical model FCC/BCC systems such as Cu/Nb.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Phase-Field Modeling of Nugget Zone for a AZ31-Mg-Alloy Friction Stir Weld

This work presents simulation of microstructure evolution in the nugget zone (NZ) of a AZ31-Mg-alloy friction stir weld. The process parameters (tool geometrical characteristics, rotational speed, travel speed, applied load) have been correlated with the resulting microstructural features in the NZ of the weld (grain size and population) with the aid of the MICRESS software, which provides the ability to simulate both nucleation and grain growth during dynamic recrystallization phenomena evolving in the NZ during the weld thermal cycle. The input parameters of the developed model include the tool geometry, the welding conditions as well as the recrystallization energy, the grain boundary mobility and specific material properties. NZ microstructure obtained by simulation shows good agreement with experimental measurements for both grain population and size.

36 MATERIALS SCIENCE↗
DOE OSTI2024

The microstructure effects on irradiation response of ferritic – martensitic steels

Microstructural optimization to achieve greater mechanical strength has been one of the focuses in ferritic–martensitic steels development. However, these optimized microstructures’ effects on the radiation response are not well known. In this work, two ferritic–martensitic steels (9Cr-NbMo and 9Cr-Ta) underwent neutron irradiation in the High Flux Isotope Reactor, and their room-temperature post-irradiation tensile properties and microstructure evolutions were investigated and compared. These two steels exhibit similar pre-irradiation tensile behavior, and their yield strengths are higher than that of other ferritic–martensitic steels by about 200–250 MPa. Microstructural characterization on pre-irradiated materials reveals a smaller grain size in 9Cr-Ta (2.8 ± 0.3 μm in 9Cr-Ta versus 4.3 ± 0.5 μm in 9Cr-NbMo) but higher dislocation density and precipitate density in 9Cr-NbMo. As is common for ferritic–martensitic steels at low irradiation temperatures (less than about 0.45T m ), irradiation-induced hardening at 400 °C was observed for both alloys. Irradiation at 490 °C causes the two alloys to exhibit different tensile behavior: 9Cr-Ta softens by 208 MPa in yield stress, whereas 9Cr-NbMo maintains strength. Additionally, microstructural characterizations were performed, including precipitate growth, dislocation, and defect formation. Using the barrier hardening model for microstructure–property correlation, the softening in irradiated 9Cr-Ta is primarily attributed to the significant dislocation recovery, while the strength lost from the slight dislocation recovery in 9Cr-NbMo was compensated by the additional strength from the irradiation-induced cavities. The microstructure effect (primarily precipitate, dislocation and boundary) on the radiation response is discussed herein.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Effect of heat treatment on the microstructure of medium burn-up U-Mo monolithic fuel foils

Using scanning electron microscopy (SEM), this study evaluates the microstructure evolution of U-Mo fuel foils made with and without heat treatment at medium burn-up (of approximately 5 x 10 21 f/cm 3 ). The impact of annealing treatments on critical microstructural properties of the U-Mo fuel foils, including porosity, grain structure, Mo homogeneity, and fuel interaction with the Zr interlayer, was examined using large area lift outs (LALOs). The heat-treated specimens presented less grain refining at these burnups when compared to the un-heated specimens. Grain refinement was associated with porosities and fission products precipitation. Heat treatment can reduce fuel swelling during irradiation. Chemical inhomogeneity (Mo banding) was found to persist in the un-heated samples but was not present in the heat-treated samples. Thus, heat-treated U-Mo foils allows for more predictable fuel behavior under irradiation with respect to un-heated foils. The U-Mo and Zr interaction layer appears to be thicker and more continuous in the heat-treated sample which has been associated with stronger interface integrity during irradiation, as also observed in previous studies. These observations may indicate an overall improved performance of heat-treated fuel foil in a reactor. Further, the effect of local burn-up on grain size/refinement and porosities in each LALO specimen, sampled from different positions in the fuel foil, was difficult to analyze due to the large standard deviation of these parameters. Finally, evidence of grain refinement by polygonization may be present in these specimens.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Parallel simulation via SPPARKS of on-lattice kinetic and Metropolis Monte Carlo models for materials processing

Abstract SPPARKS is an open-source parallel simulation code for developing and running various kinds of on-lattice Monte Carlo models at the atomic or meso scales. It can be used to study the properties of solid-state materials as well as model their dynamic evolution during processing. The modular nature of the code allows new models and diagnostic computations to be added without modification to its core functionality, including its parallel algorithms. A variety of models for microstructural evolution (grain growth), solid-state diffusion, thin film deposition, and additive manufacturing (AM) processes are included in the code. SPPARKS can also be used to implement grid-based algorithms such as phase field or cellular automata models, to run either in tandem with a Monte Carlo method or independently. For very large systems such as AM applications, the Stitch I/O library is included, which enables only a small portion of a huge system to be resident in memory. In this paper we describe SPPARKS and its parallel algorithms and performance, explain how new Monte Carlo models can be added, and highlight a variety of applications which have been developed within the code.

36 MATERIALS SCIENCE↗
DOE OSTI2017

On the role of precursor powder composition in controlling microstructure, flux pinning, and the critical current density of Ag/Bi$_2$Sr$_2$CaCu$_2$O$_x$ conductors

Precursor powder composition is known to strongly affect the critical current density (J c ) of Ag/Bi$_2$Sr$_2$CaCu$_2$O$_x$ (Bi-2212) wires. However, reasons for such J c dependence have not yet been fully understood, compromising our ability to achieve further optimization. In this paper, we systematically examined superconducting properties, microstructural evolution and phase transformation, and grain boundaries of Bi-2212 conductors fabricated from precursor powders with a range of compositions using a combination of transport-current measurements, a quench technique to freeze microstructures at high temperatures during heat treatment, and scanning transmission electron microscopy (STEM). Samples include both dip-coated tapes and round wires, among which a commercial round wire carries a high J c of 7600 A mm -2 at 4.2 K, self-field and 2600 A mm -2 at 4.2 K, 20 T, respectively. In the melt, this high-J c conductor, made using a composition of Bi 2.17 Sr 1.94 Ca 0.89 Cu 2 O x , contains a uniform dispersion of fine alkaline-earth cuprate (AEC) and copper-free solid phases, whereas several low-J c conductors contain large AEC particles. Such significant differences in the phase morphologies in the melt are accompanied by a drastic difference in the formation kinetics of Bi-2212 during recrystallization cooling. STEM studies show that Bi-2212 grain colonies in the high-J c conductors have a high density of Bi 2 Sr 2 CuO y (Bi-2201) intergrowths, whereas a low-J c conductor, made using Bi 2.14 Sr 1.66 Ca 1.24 Cu 1.96 O x , is nearly free of them. STEM investigation shows grain boundaries in low-J c conductors are often insulated with a Bi-rich amorphous phase. Finally, high-J c conductors also show higher flux-pinning strength, which we ascribe to their higher Bi-2201 intergrowth density.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2024

Improving Additive Manufactured Component Performance through Multi-Scale Microstructure Simulation and Process Optimization

The purpose of this project was to utilize computational tools to understand the relationships between processing, microstructure, and properties for additively manufactured (AM) aluminum alloys for automotive applications, and to provide an engineering solution for helping to optimize process conditions. The project leverages ORNL developments in computational modeling, including AM process modeling, phase-field based microstructure evolution predictions, and data analytics techniques for mapping process conditions to material outcomes. The project utilized an Al-Cu-Mn-Zr alloy as a model material for studying formation of defects and microstructural features in response to variations in process conditions. Based on both pre-existing experimental data and simulation results, statistical process maps were constructed to identify regions of process space with minimal defect formation and advantageous microstructures and properties. The software tools used for this purpose were successful disseminated to GM, who were able to successful compile the relevant HPC codes within their own computing ecosystem and perform initial calculations to reproduce ORNL results.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Microstructural Development and Mechanical Properties of Friction Stir Welded Ferritic Stainless Steel AISI 409

This work investigates the effect of friction stir welding process parameters (rotation rate and traverse speed) on the microstructural evolution of friction stir welded (FSWed) ferritic stainless steel (FSS) AISI 409. Optical microscope, scanning electron microscope and electron backscattering diffraction are used to quantitatively assess the development in grain structure and texture. The microstructural development suggested that thermo-mechanical deformation occurs in the stir zone within the austenite/ferrite phase region, ultimately transforming upon cooling into bainitic/ferritic microstructure. The fraction and size of the bainitic/ferritic grains are found to vary through the thickness of the joints. High fractions of coarse ferritic grains are found near the top of the stir zone, and low fraction of fine ferritic grains is found near the bottom of the stir zone. This bainitic/ferritic grain structure resulted in an increase in the hardness of the stir zone by about 74% relative to the base material. The tensile strength of the FSWed FSS joints is almost at the same level of the base material with reduction in the ductility as a result of the increased hardness of the weld zone.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Investigation on temporal evolution of the grain refinement in copper under high strain rate loading via in-situ synchrotron measurement and predictive modeling

Synchrotron X-rays are integrated with a modified Kolsky tension bar to conduct in situ tracking of the grain refinement mechanism operating during the dynamic deformation of metals. Copper with an initial average grain size of 36 μm is refined to 6.3 μm when loaded at a constant high strain rate of 1200 s -1 . The synchrotron measurements revealed the temporal evolution of the grain refinement mechanism in terms of the initiation and rate of refinement throughout the loading test. A multiscale coupled probabilistic cellular automata based recrystallization model has been developed to predict the microstructural evolution occurring during dynamic deformation processes. The model accurately predicts the initiation of the grain refinement mechanism with a predicted final average grain size of 2.4 μm. As a result, the model also accurately predicts the temporal evolution in terms of the initiation and extent of refinement when compared with the experimental results.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Microstructure, texture and mechanical properties of 6061 aluminum laser beam welded joints

Highlights: • Strong cube texture ({001}<100>) is observed in columnar dendrites. • The ratio of equiaxed dendrites shows proportional relationship with the strength. • The relations between process-microstructure-property are accurately established. - Abstract: In the present study, laser beam welding was carried out with 6061 Al alloy plate to study the microstructural evolution under various welding heat input (ηP/v = 30 J/mm, 38 J/mm, 46 J/mm, and 58 J/mm). The width of the weld metals increased continuously with the heat input values. Quantitatively correlation of the microstructure distribution with welding parameters was developed based on the EBSD results. The weld metals mainly consisted of coarse columnar dendrites and equiaxed dendrites. The ratio of equiaxed dendrites which were controlled by constitutional supercooling and heterogeneous nuclei showed directly proportional relationship with the weld strength. Strong cube texture ({001}<100>) was observed in columnar dendrites, which showed harmful effect on the weld strength. Slight softening in heat affected zone due to recrystallization was identified by nanoindentation tests. All specimens failed in weld metal and the fracture surfaces showed the characteristics of ductile fracture.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Laser Additive Manufacturing of F/M Steels for Radiation Tolerant Nuclear Components

According to the Nuclear Energy R&D Roadmap Report submitted to Congress in 2010, one the key challenges facing the nuclear energy industry involves development of new reactor designs with reduced capital costs. Two related R&D objectives outlined in the report include: 1) Making improvements in the affordability of new reactors; and 2) Development of structural materials to withstand irradiation for longer periods. Laser additive manufacturing (LAM) is particularly well suited for more rapid and economical fabrication of reactor components relative to current fabrication methods. The proposed work involving LAM directly addresses the two R&D objectives outlined above relevant to the pertinent mission problems. The classical Materials Science approach involving development of Process/Structure/Property/Performance (P/S/P/P) relations was employed in this project. Processing included LAM and heat-treating. Thermal cycling during LAM is discussed here, and phase diagrams and continuous cooling transformation (CCT) diagrams are used to rationalize microstructural evolution. Structures were characterized including grain size & morphology, volume fraction, morphology, composition and location of carbides in as-deposited and heat-treated conditions. In the simplest sense, the goal was to control microstructures through process manipulation with a view toward optimizing properties and performance in service.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2026

Microstructure Validation of Graph Theory Model-Derived Cooling Rates in the Wire Arc Additive Manufacturing of ER70S-6 Steel

Wire arc additive manufacturing (WAAM) enables high-rate fabrication of large metallic components, but spatial variations in thermal history can lead to microstructural heterogeneity that requires efficient process models to evaluate. This study evaluates whether cooling rates extracted from a graph theory model (GTM)-based thermal simulation are consistent with the microstructural evolution observed in an ER70S-6 WAAM wall. Thermal histories from the model were analyzed at selected build heights, and cooling rates were extracted from the final thermal excursion through the austenite phase field. Microstructures at corresponding locations were characterized using electron backscatter diffraction (EBSD) to quantify grain size distributions, and pearlite interlamellar spacing was used as an additional indicator of cooling behavior. The modeled cooling rates were highest near the substrate and generally decreased with build height, consistent with the observed reduction in the fine grain fraction and the progressive shift in the grain size distribution as build height increased. Pearlite spacing trends also supported the modeled cooling rate variation. These results indicate that GTM-derived thermal histories can be post-processed into metallurgically meaningful cooling rate estimates for WAAM steel builds and linked to dataset specific empirical grain size distribution relationships for process–thermal history–microstructure assessment.

36 MATERIALS SCIENCE↗
NASA NTRS1993

Microstructural stability of wrought, laser and electron beam glazed NARloy-Z alloy at elevated temperatures

Microstructure of wrought, laser, and electron-beam glazed NARloy-Z(Cu-3 wt.% Ag-0.5 wt.% Zr) was investigated for thermal stability at elevated temperatures (539 to 760 C (1,100 to 1,400 F)) up to 94 h. Optical and scanning electron microscopy and electron probe microanalysis were employed for studying microstructural evolution and kinetics of precipitation. Grain boundary precipitation and precipitate free zones (PFZ's) were observed in the wrought alloy after exposing to temperatures above 605 C (1,120 F). The fine-grained microstructure observed in the laser and electron-beam glazed NARloy-Z was much more stable at elevated temperatures. Microstructural changes correlated well with hardness measurements.

Singh, J.↗
DOE OSTI2025

Implementation of disruptive designs for gas turbine components using direct energy deposition additive manufacturing

This research aims to develop a framework for establishing the correlation between in-situ monitoring data, process parameters, and microstructure evolution in blown-powder laser-directed energy deposition (DED) additive manufacturing (AM). To achieve this, a comprehensive manufacturing framework has been developed, spanning from in-situ data acquisition, melt-pool simulation, microstructure modeling, and statistical microstructure quantification. A machine learning-based surrogate model is constructed to predict melt pool geometry directly from in-situ coaxial camera data. The surrogate model is trained using outputs from a high-fidelity melt pool simulation, which provides accurate melt pool dimension data under varying process conditions. The predicted melt pool geometry is then used as input to a microstructure model to predict microstructural features. To rigorously compare and analyze microstructures, the project introduces statistical metrics that quantify differences based on key features such as morphology and texture. Microstructures are represented using advanced statistical descriptors including angular chord length distribution, two-point spatial statistics, orientation distribution function, and global spherical harmonic. These representations are used to compute four distinct “dissimilarity scores” that quantitatively capture differences in texture and morphology. This framework is demonstrated to enable automated calibration of simulation parameters by minimizing discrepancies between simulated and target microstructures. The technology developed in this project enables direct correlation between in-situ monitoring data and resulting microstructure, paving the way for adaptive microstructure control in metal AM. This capability strengthens the connection between process parameters and final material properties, facilitating more precise and reliable material design.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Evolution of grain boundary character distributions in alloy 825 tubes during high temperature annealing: Is grain boundary engineering achieved through recrystallization or grain growth?

Grain boundary engineering (GBE) of nickel-based alloy 825 tubes was carried out with different cold drawing deformations by using a draw-bench on a factory production line and subsequent annealing at various temperatures. The microstructure evolution of alloy 825 during thermal-mechanical processing (TMP) was characterized by means of the electron backscatter diffraction (EBSD) technique to study the TMP effects on the grain boundary network and the evolution of grain boundary character distributions during high temperature annealing. The results showed that the proportion of ∑ 3{sup n} coincidence site lattice (CSL) boundaries of alloy 825 tubes could be increased to > 75% by the TMP of 5% cold drawing and subsequent annealing at 1050 °C for 10 min. The microstructures of the partially recrystallized samples and the fully recrystallized samples suggested that the proportion of low ∑ CSL grain boundaries depended on the annealing time. The frequency of low ∑ CSL grain boundaries increases rapidly with increasing annealing time associating with the formation of large-size highly-twinned grains-cluster microstructure during recrystallization. However, upon further increasing annealing time, the frequency of low ∑ CSL grain boundaries decreased markedly during grain growth. So it is concluded that grain boundary engineering is achieved through recrystallization rather than grain growth. - Highlights: •The grain boundary engineering (GBE) is applicable to 825 tubes. •GBE is achieved through recrystallization rather than grain growth. •The low ∑ CSL grain boundaries in 825 tubes can be increased to > 75%.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Effect of Heat Treatment on Microstructure and Mechanical Properties of Stellite 12 Fabricated by Laser Additive Manufacturing

Microstructure evolution and wear resistance of Stellite 12 produced by laser additive manufacturing were studied in untreated and heat-treated conditions. In untreated conditions, cobalt matrix dendrites and inter-dendritic eutectic carbides were the primary microstructure, blocky and lamellar eutectic carbides can be found, and M{sub 7}C{sub 3} and M{sub 23}C{sub 6} are the primary carbides. Heat treatment can modify the microstructure of this alloy. Primary carbides were dissolved into the cobalt matrix after solution treatment. Aging treatment resulted in the precipitation of carbides, the transformation of M{sub 7}C{sub 3} into M{sub 23}C{sub 6} carbides, and the increase in microhardness. Solution and aging treatment can also cause the precipitation of carbides, but the morphology and distribution of carbides were absolutely different. The wear resistance of untreated samples at room temperature (RT) and 600 °C is better than that at 200 and 400 °C due to the high hardness at RT and the formation of oxide film at 600 °C. The wear resistance of heat-treated samples was tested at 600 °C; it was dominated by the formation and flake-off of oxide film. The sample that underwent solution plus aging treatment has a superior wear resistance.

36 MATERIALS SCIENCE↗