Search NASA⌕ Search

SEARCH · Search NASA

Results for “microstructure evolution”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 775 records · Page 43
All sourcesNASA NTRSDOE OSTI
DOE OSTI2013

Efficient simulation of press hardening process through integrated structural and CFD analyses

Press hardened steel parts are being increasingly used in automotive structures for their higher strength to meet safety standards while reducing vehicle weight to improve fuel consumption. However, manufacturing of sheet metal parts by press hardening process to achieve desired properties is extremely challenging as it involves complex interaction of plastic deformation, metallurgical change, thermal distribution, and fluid flow. Numerical simulation is critical for successful design of the process and to understand the interaction among the numerous process parameters to control the press hardening process in order to consistently achieve desired part properties. Until now there has been no integrated commercial software solution that can efficiently model the complete process from forming of the blank, heat transfer between the blank and tool, microstructure evolution in the blank, heat loss from tool to the fluid that flows through water channels in the tools. In this study, a numerical solution based on Altair HyperWorks® product suite involving RADIOSS®, a non-linear finite element based structural analysis solver and AcuSolve®, an incompressible fluid flow solver based on Galerkin Least Square Finite Element Method have been utilized to develop an efficient solution for complete press hardening process design and analysis. RADIOSS is used to handle the plastic deformation, heat transfer between the blank and tool, and microstructure evolution in the blank during cooling. While AcuSolve is used to efficiently model heat loss from tool to the fluid that flows through water channels in the tools. The approach is demonstrated through some case studies.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Microstructures and mechanical properties of the welded AA5182/HC340LA joint by magnetic pulse welding

Highlights: • The magnetic pulse welding of 5× aluminum alloy with high strength steel is performed. • The microstructure evolution of welding interface under different parameters is investigated. • The intermediate layer is characterized by high-resolution transmission electron microscope and electron diffraction pattern. - Abstract: Magnetic pulse welding (MPW) is an innovative joining technology for dissimilar materials. The MPW with high joining qualities could be realized between high strength steel and 5× aluminum alloys. In this work, the MPW joints between aluminum alloy (AA 5182) sheet and high-strength low alloy steel (HC340LA) sheet were prepared under various discharge energies. The mechanical properties and microstructure observations were employed to evaluate the joint performance. Results showed that a lower discharge voltage tended to cause joints with poor quality. When the discharge energy increased, the failure position gradually changed from the weld zone to the weaker base metal (Al) during quasi-static tensile tests. In addition, the effect of discharge energies on microstructure evolution in the intermediate layer was revealed by high-resolution transmission electron microscopy (HRTEM) and scanning electron microscope (SEM). Atomic-scale diffusion was found to be the mainly welding mechanism of the Al/Fe joint. The intermetallic compound (IMC) FeAl{sub 2} and ultra-fine grains (UFG) were found in the intermediate layer under high discharge energy.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Materials for Extreme Irradiation Environments

Award DE-FG02-05ER46217 consisted of two phases: From 8/2005 to 8/2010, it supported two PIs, R. S. Averback and P. Bellon, on an effort entitled “Microstructural evolution and mechanical response of complex alloys under prolonged particle irradiation”. The results of this first phase led to the funding of a research cluster, supporting five PIs, adding Shen J. Dillon, William P. King and Dallas R. Trinkle plus Averback and Bellon, broadening the research to the study of “Materials for Extreme Irradiation Environments”. We summarize here the key findings obtained during this award, and their impact on our understanding of the fundamental aspects of microstructural evolution and mechanical properties of metallic alloys driven by irradiation or severe plastic deformation.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Understanding Formation of Irradiation-Induced Defects through 4D-STEM, Electron Tomography, and WBDF-STEM

A major challenge in advancing nuclear materials for next-generation fission and proposed fusion reactors is to comprehensively understand the formation of irradiation-induced defects. Here it is essential to correlate the evolution of irradiation-induced defects and the degradation of mechanical properties, as they collectively dictate the material's lifespan and ensure nuclear safety. Scanning transmission electron microscopy (STEM) based techniques have emerged as indispensable tools for irradiation-induced defect characterization, offering high spatial resolution imaging and chemical analysis, such as electron energy loss spectroscopy (EELS) and energy dispersive X-ray spectroscopy (EDXS). These techniques have been effectively used to obtain an atomic-scale view of the defect structure. Recent advances in electron microscopy, particularly in 4D-STEM, offer detailed insight into microstructural evolution by capturing full 2D diffraction patterns at every pixel position. Using high-speed direct electron detectors, this technology generates a four-dimensional dataset, overcoming the limitations of traditional STEM imaging.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Annealing Effects on Microstructure and Mechanical Properties of Ultrafine-Grained Al Composites Reinforced with Nano-Al{sub 2}O{sub 3} by Rotary Swaging

Microstructure evolution and variations in mechanical properties of Al-Al{sub 2}O{sub 3} nanocomposite produced by powder metallurgy were investigated and compared with commercially pure aluminum (Al-1050) after furnace annealing. Fine gas-atomized Al powder compacts were first sintered in flowing nitrogen, subsequently consolidated into wires by rotary swaging and eventually annealed at 300 and 500 °C for 24 h each. Scanning and transmission electron microscopy with energy-dispersive spectroscopy was utilized to document the microstructure evolution. Rotary swaging was proven to lead to a marked decrease in grain size. After heavy swaging to true deformation degree of φ = 6 and annealing at 500 °C, obvious recrystallization was observed at Al-1050’s existing grain boundaries and the crystals began to grow perpendicular to the flow direction. In the Al-Al{sub 2}O{sub 3} nanocomposite, fabricated from d{sub 50} = 6 μm Al powder, recrystallization partially occurred, while grains were still extremely fine. Due to the dual role of fine-grained Al{sub 2}O{sub 3} dispersion strengthening, the nanocomposite showed improved mechanical performance in terms of tensile strength, approximately twice higher than Al-1050 after annealing at 500 °C.

36 MATERIALS SCIENCE↗
DOE OSTI2025

In situ irradiation of spent nuclear fuels

To improve the economics of commercial nuclear reactors, nuclear vendors and utilities are seeking approval for increased burnup usage of the existing nuclear fleet. This is especially critical for meeting the clean energy initiative by the United States Government, Department of Energy (DOE). However, one of the key challenges the nuclear industry faces in this regard is that the regions exposed to high burnup and low temperatures exhibit a fine-grained microstructure with large bubbles known as high-burnup structure (HBS) [1]. The formation of HBS has been correlated to the diminished performance of the reactor, as well as fuel fragmentation and pulverization during transient and accidental conditions [2]. Therefore, it is paramount to understand the mechanisms for HBS formation along with its impact on the properties and performance of nuclear fuels. While existing programs, such as Nuclear Energy Advanced Modeling and Simulation (NEAMS) and Advanced Fuel Campaign (AFC) are focusing on evaluating the performance impact of HBS, the physical mechanisms contributing to HBS formation are still not fully understood. In addition, having predictive capabilities and sound understanding of the microstructural evolution of nuclear fuel is essential for accelerated development, qualification, and deployment of new nuclear materials and novel reactor designs for advanced nuclear reactors. There is a lack of consensus among researchers regarding the mechanisms leading to such restructuring observed in HBS. Grain subdivision due to polygonization versus recrystallization, continuous versus discrete recrystallization occurring in tandem or conjunction, etc., have been proposed and debated. In general, it is hypothesized that defect accumulation and dislocation interaction within the grains cause the realignment of dislocations into grain boundaries, leading to the new subgrain formation, which over time transforms into new grains. However, due to the lack of transient data, the importance of fission rate, irradiation, thermal, and stress history of the fuel on the restructuring could not be assessed. In situ microstructural evolution under various irradiation conditions is desired to bridge this gap. Alternatively, phase-field-based models have been developed to capture HBS formation via discrete recrystallization utilizing the classical nucleation approach [3–5]. However, in these models, the grain nucleation criteria are often defined based on empirical relations for burnup and fission gas density leading to dislocation density change. A mechanistic approach to capture the dislocation interaction with the microstructural features leading to grain subdivision is lacking.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

The Mechanical and Microstructural Changes of Sn-Ag-Bi Solders with Cooling Rate and Bi Content Variations

The purpose of this study is to investigate the influence of cooling rate and Bi addition on the microstructure evolution and mechanical properties of Sn-3.5Ag alloy. A series of Sn-3.5Ag-xBi solders has been fabricated with Bi content in the range of 0.5-3.5 wt.%. After solution heat treatment at 170 °C for 24 h and subsequent aging heat treatment at 100 °C for 2 h, samples were divided into two groups. One group was rapidly quenched into iced water (water quenching) for the fast cooling rate (20 °C/s), while the second group was slowly cooled (furnace cooling) in the furnace for the slow cooling rate (0.2 °C/s) after the furnace reflow. The microstructural evolutions of the present solders have been investigated using x-ray diffraction and scanning electron microscopy. The microhardness was measured to correlate the mechanical properties to alloy compositions and cooling rate. It was found that the microhardness of Sn-3.5Ag-xBi solders increased with increasing cooling rate. The indentation creep curves have been evaluated from the obtained microhardness values. Results revealed the steady-state creep rate decreased with increasing Bi content exhibiting an anomalous behavior at 2.5Bi. The reason for improved creep resistance of Sn-3.5Ag-xBi solders is the result of the combination of the solid solution strengthening and precipitation strengthening of Bi. The mean values of stress exponent indicated that the operative creep mechanism is dislocation climb.

36 MATERIALS SCIENCE↗
DOE OSTI2019

A two-set order parameters phase-field modeling of crack deflection/penetration in a heterogeneous microstructure

Modeling of crack deflection/penetration or manifested as intergranular/transgranular fracture in polycrystals has long been a challenge in both fracture mechanics and materials science. A phase-field model formulated with two-set order parameters describing the crack field and the microstructure field respectively, is herein established to investigate the competition between crack penetration and deflection at an interface. The advantages of the proposed model are three-fold: (1) the fracture toughness of grain boundaries and/or interfaces, besides single crystal properties (e.g., Young’s modulus, Poisson ratio, and fracture toughness), can be automatically incorporated, (2) cohesive interfaces are treated in one phase-field framework in comparison with the integrated phase-field and cohesive zone model in which cohesive elements have to be manually placed at the interface, and (3) two-set order parameters enable to describe the concurrent crack propagation and microstructure evolution. The proposed model is validated by comparing the simulated critical deflection angles with the results from theoretical analysis of the linear elastic fracture mechanics and the experiments. The model is then applied to a heterogeneous Silicon Nitride polycrystal to determine the effect of interface fracture toughness on the intergranular/transgranular fracture transition and the effective toughness of the materials.

Chen, Hu↗
DOE OSTI2014

A cellular automaton method to simulate the microstructure and evolution of low-enriched uranium (LEU) U–Mo/Al dispersion type fuel plates

Low-enriched uranium (LEU) fuel plates for high power materials test reactors (MTR) are composed of nominally spherical uranium-molybdenum (U-Mo) particles within an aluminum matrix. Fresh U-Mo particles typically range between 10 and 100 mu m in diameter, with particle volume fractions up to 50%. As the fuel ages, reaction-diffusion processes cause the formation and growth of interaction layers that surround the fuel particles. The growth rate depends upon the temperature and radiation environment. The cellular automaton algorithm described in this paper can synthesize realistic random fuel-particle structures and simulate the growth of the intermetallic interaction layers. Examples in the present paper pack approximately 1000 particles into three-dimensional rectangular fuel structures that are approximately 1 mm on each side. The computational approach is designed to yield synthetic microstructures consistent with images from actual fuel plates and is validated by comparison with empirical data on actual fuel plates. (C) 2014 Elsevier B.V. All rights reserved.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2013

Fracture modes in tubular LSFCO ceramic membranes under graded reducing conditions

Highlights: ► Microstructural evolution in LSFCO membranes under graded environment is reported. ► The role of chemically induced stresses and oxygen deficiency is evaluated. ► The stress distribution is modeled by a point defect model. - Abstract: Chromium (III) oxide (Cr{sub 2}O{sub 3})-doped LaSrFeO{sub 3} perovskite, La{sub 0.2}Sr{sub 0.8}Fe{sub 0.8}Cr{sub 0.2}O{sub 3−δ} (LSFCO), is being considered as a potential material for applications in solid oxide fuel cells, gas separation membranes, and electrochemical reactors because of its high electro-catalytic activity. Similar to other perovskites, the performance and mechanical strength of LSFCO materials are significantly affected by environment and temperature. Here, we report a fracture gradient phenomenon in tubular C-ring-shaped LSFCO ceramic membranes under graded reducing conditions. The graded reducing condition was produced by flushing N{sub 2} on the outer side of the C-ring membranes at 1000 °C while keeping the inner side untreated. The rings were then diametrically compressed to fracture, and the resultant fracture morphology was analyzed with a scanning electron microscope (SEM). A fracture gradient with three distinct regions across the thickness of the membranes was identified on the split surfaces. In the outer region of the C-ring specimen exposed to N{sub 2}, a mixed inter/transgranular fracture with a predominant intergranular pattern was observed. In the middle section of the fracture surface, a characteristic transgranular fracture of the perovskite grains was found. At the inner region of the ring, a mixed inter/transgranular fracture with a predominant transgranular pattern occurred. The mechanism of gradient fractures was attributed both to chemically induced stresses caused by oxygen diffusion and to the formation of a separate phase of oxygen-deficient perovskite in the parent perovskite. The stresses generated were modeled by a point defect model. This work provides significant information on microstructure evolutions of tubular LSFCO membranes under graded reducing atmospheres.

36 MATERIALS SCIENCE↗
DOE OSTI2019

The effect of thermal-aging on the microstructure and mechanical properties of 9Cr ferritic/martensitic ODS alloy

In this paper, the thermal-stability of 9Cr F/M ODS alloy was evaluated by the aging treatment in the air at 700 degrees C for 10 h, 100 h, 1000 h, and 2005 h. The variations of mechanical properties with different aging periods were tested in terms of tensile testing and vickers microhardness. And the microstructural evolution of strengthening particles and grain morphologies in the 9Cr F/M ODS alloys were characterized using field emission scanning electron microscopy, transmission electron microscopy and high-energy X-ray diffraction. It was found that the as-rolled 9Cr F/M ODS alloy slightly recovered without recrystallization during the initial stage of less than 10 h aging time, resulting in the slight loss of tensile strength and microhardness and the increase of elongation. With the aging time prolonged to 2005 h, several of nano-sized Y-Ti-O particles coarsened and the composition changed to Y-Ti-Al-O, and the number density of large size nitride precipitations increased and the composition also changed from TiN to (Ti,AI)N. Meanwhile, some of grains tend to grow up in some preferential directions due to the zener pinning effect by the localized uneven distributed particles inside the grains, causing more particles, especially the particles with a size of larger than 40 nm, located at grain boundaries. These microstructural evolutions lead to the increasing of microhardness and a little bit decreasing of eleongation during 10 h-2005 h, and the increasing of tensile strength during 10 h-1000 h with the subsequent slight decreasing during 1000 h-2005 h. In conclusion, 9Cr F/M alloy shows a relatively good thermal-aging stability at 700 degrees C for 2005 h.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Combined Torsion and Tension on the Microstructure and Fracture Behavior of 316L Austenitic Stainless Steel

In this study, the microstructure evolution and fracture behavior of 316L austenitic stainless steel (ASS) deformed by torsion–tension at room temperature was systematically investigated. During combined tension and torsion, the grain size was refined with increasing shear strain. In addition, the microtexture exhibited a preferred orientation with increasing shear stress. The metastable austenite underwent phase transition when the shear stress increased. The shear stress affected the fracture morphology, and dimples with different sizes and depths were observed for different pre-torsions. The dislocation density increased significantly owing to severe shear deformation. In addition, the dislocation structure evolved and subgrains appeared with the accumulation of shear strain during this combined deformation. The result showed that pre-torsion deformation plays an important role in improving the comprehensive performance and controlling the microstructure evolution of the sample subjected to tension deformation.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Radiation Damage in Materials—Helium Effects

Despite its scarcity in terrestrial life, helium effects on microstructure evolution and thermo-mechanical properties can have a significant impact on the operation and lifetime of applications, including: advanced structural steels in fast fission reactors, plasma facing and structural materials in fusion devices, spallation neutron target designs, energetic alpha emissions in actinides, helium precipitation in tritium-containing materials, and nuclear waste materials. The small size of a helium atom combined with its near insolubility in almost every solid makes the helium–solid interaction extremely complex over multiple length and time scales. This Special Issue, “Radiation Damage in Materials—Helium Effects”, contains review articles and full-length papers on new irradiation material research activities and novel material ideas using experimental and/or modeling approaches. These studies elucidate the interactions of helium with various extreme environments and tailored nanostructures, as well as their impact on microstructural evolution and material properties.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Role of the interface on radiation damage in the SrTiO{sub 3}/LaAlO{sub 3} heterostructure under Ne{sup 2+} ion irradiation

We systematically investigated the microstructural evolution of heteroepitaxial SrTiO{sub 3} (STO) thin films grown on a single crystal LaAlO{sub 3} (LAO) (001) substrate, focusing on the response of the STO/LAO interface to Ne{sup 2+} irradiation at room temperature. Cross sectional transmission electron microscope (TEM) analysis reveals that the LAO crystal amorphizes first after a relatively low dose of damage followed by the amorphization of the STO film after irradiation to a higher dose. While the critical dose to amorphize differs between each material, amorphization begins at the interface and proceeds outward in both cases. Thus, a crystalline/amorphous interface first forms at the STO/LAO interface by a dose of 1 dpa, and then an amorphous/amorphous interface forms when the dose reaches 3 dpa. Scanning TEM and x-ray energy dispersive spectroscopy indicate no significant heavy cation elemental diffusion, though electron energy loss spectroscopy reveals a redistribution of oxygen across the film/substrate interface after Ne{sup 2+} irradiation. Atomistic calculations are used to interpret the experimental findings in terms of the defect properties in each of the two component phases.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2010

Kr Ion Irradiation Study of the Depleted-Uranium Alloys

Fuel development for the Reduced Enrichment Research and Test Reactor program is tasked with the development of new low-enriched uranium nuclear fuels that can be employed to replace existing highly enriched uranium fuels currently used in some research reactors throughout the world. For dispersion-type fuels, radiation stability of the fuel/cladding interaction product has a strong impact on fuel performance. Three depleted uranium alloys are cast for the radiation stability studies of the fuel/cladding interaction product using Kr ion irradiation to investigate radiation damage from fission products. SEM analysis indicates the presence of the phases of interest: U(Si, Al)3, (U, Mo)(Si, Al)3, UMo2Al20, U6Mo4Al43, and UAl4. Irradiations of TEM disc samples were conducted with 500 keV Kr ions at 200ºC to ion doses up to 2.5 × 1015 ions/cm2 (~ 10 dpa) with an Kr ion flux of 1012 ions/cm2-sec (~ 4.0 × 10-3 dpa/sec). Microstructural evolution of the phases relevant to fuel-cladding interaction products was investigated using transmission electron microscopy.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2019

Thermal stability and irradiation response of nanocrystalline CoCrCuFeNi high-entropy alloy

Grain growth and phase stability of a nanocrystalline face-centered cubic (fcc) Ni 0.2 Fe 0.2 Co 0.2 Cr 0.2 Cu 0.2 high-entropy alloy (HEA), either thermally- or irradiation-induced, are investigated through in situ and post-irradiation transmission electron microscopy (TEM) characterization. Synchrotron and lab x-ray diffraction measurements are carried out to determine the microstructural evolution and phase stability with improved statistics. Under in situ TEM observation, the fcc structure is stable at 300 °C with a small amount of grain growth from 15.8 to ~20 nm being observed after 1800 s. At 500 °C, however, some abnormal growth activities are observed after 1400 s, and secondary phases are formed. Under 3 MeV Ni room temperature ion irradiation up to an extreme dose of nearly 600 displacements per atom, the fcc phase is stable and the average grain size increases from 15.6 to 25.2 nm. Lastly, grain growth mechanisms driven by grain rotation, grain boundary curvature, and disorder are discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Elucidating Abnormal Grain Growth in Thermomagnetic Processed Materials with Transfer Learning and Reinforcement Learning

The goal of this research program is to establish the mechanism governing local grain boundary motion, which is needed to design and process desirable microstructures for better performance, by identifying the relative contributions of grain boundary (GB) energy and mobility to grain growth. Classical models for grain growth assume that the primary mechanism for reducing the total interfacial energy is area reduction and that GB restructuring is not significant. This assumption implies that grain growth is locally driven by curvature. However, recent experimental observations using new non-destructive 3D x-ray diffraction microscopy techniques (3D-XRM) reveal that classic descriptors (i.e., curvature, number of neighbors, grain size) do not predict real grain growth. Instead, local GB motion appears to be governed by its energy relative to its neighbors such that low-energy boundaries replace those of higher energy. However, simulations that incorporate GB energy anisotropy still fail to reproduce these observations. These discrepancies suggest that the common assumption for grain growth theory must be re-examined to predict and, thus, control microstructure evolution in real polycrystals. A significant challenge to testing this assumption is due to anisotropic GB mobility. Mobility may cause abnormal grain growth or affect the final grain shapes or growth rate but its true contributions are unknown because it is difficult to measure. For example, observations in Fe have found that grains associated with high energy and high mobility boundaries tend to experience abnormal grain growth, whereas abnormal grain growth is associated with low energy and high mobility boundaries in alumina. As mobility and energy both control GB motion, it is challenging to isolate the local driving forces necessary to test the common assumption that the primary mechanism is area reduction. The novelty of this work is the use of machine learning tools to capture GB mobility and energy from 3D-XRM measurements in polycrystals to test the common assumption used in grain growth models. Machine learning can capture high-order correlations in dynamic systems like those found in the evolving GB topology. The PIs have developed a physics-regularized interpretable machine learning microstructure evolution (PRIMME) model that accurately replicates the grain growth behavior of its trained data set.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Self-interstitial configurations in hcp Zr: a first principles analysis

Analysis of microstructure evolution in irradiated Zr and Zr alloys based on the modern radiation damage theory suggests some important features of self-interstitial atoms (SIAs). Alignment of vacancy loops and voids along basal planes requires anisotropic interstitial transport with a dominant contribution along the basal plane. Under neutron irradiation this can be explained by one-dimensional mobility of SIA clusters but experiments under electron irradiation indicate unambiguously that even the single SIA should exhibit anisotropic diffusion. No experimental information is available on SIA properties in Zr and the data obtained by ab initio calculations within the last decade reported stable SIA configurations that should provide essentially three-dimensional diffusion. To clarify this issue, an extensive investigation of SIAs in Zr has been performed from first principles using two different codes. It was demonstrated that simulation cell size, type of pseudopotential, the exchange-correlation functional, and the c/a ratio are crucially important for determining the properties of interstitials in hcp Zr. The most stable SIA configurations lie in the basal plane, which should lead to SIA diffusion mainly along basal planes. The results provide a confirmation of basic mechanisms for microstructural evolution under irradiation.

Samolyuk, German D↗