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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 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Cryo-quenched Fe–Ni–Cr alloy decorative steel single crystals II: Alloy phases, structure, hardness, tensile, tribological, magnetic and electronic properties

We have previously reported (Boatner et al., J. Alloys Compd. 691 (2017) 666–671) on the discovery, formation, processing, and application of a new decorative ternary steel alloy and on its use in a wide range of practical applications including: custom and commercial knives, art objects, jewelry, electronics, and furniture. This decorative property results when polished single crystals of the 70 wt%Fe-15 wt%Ni-15 wt% Cr austenitic alloy are cryo-quenched into the martensitic phase resulting in the formation of a three-dimensional raised pattern of mixed austenitic/martensitic laths. These laths propagate across large dimensions of the material due to the absence of grain boundaries in the single crystal. The macroscopic optically reflective 3-D decorative pattern reproduces the structural symmetry inherent in the single-crystal orientation. This pattern results solely from the metallurgical phase properties of the ternary alloy and is completely distinct from the properties of Damascus steels or more modern so-called pattern-welded steels. Here we use X-ray diffraction, nanoindentation, hardness measurements/scratch testing, tribological measurements, and alloy resistivity and magnetization methods to obtain a more fundamental and comprehensive study of the effects of the austenitic/martensitic phase transition on the structural and physical properties of the 70 wt%Fe-15 wt%Ni-15 wt% Cr alloy. These results reveal new insight into irreversible phenomena that are associated with the inhibited phase transition on heating of the two-phase, mixed austenitic/martensitic structure that is formed subsequent to cryo-quenching the alloy crystal to 77 K.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Designing Multiscale Porous Metal by Simple Dealloying with 3D Morphological Evolution Mechanism Revealed via X-ray Nano-tomography

Designing materials with multiscale, hierarchical structure is critical to drive the advancement of new technology. Specifically, porous metals with multiscale porosity from nanometer to micrometer sizes would lead to enhanced physical and chemical properties—the micron-sized pores can increase the effective diffusivity of ion transport within the porous media, and the nano-sized pores provide high specific surface area, enabling functionalities that are unique to nanoporous metals. A new ternary precursor alloy selection concept utilizing the different mixing enthalpies is demonstrated in this work for the design of multiscale, bimodal porous copper from a simple, one-step dealloying of Cu–Fe–Al ternary alloy. The nanoporosity in the bimodal porous structure is formed from dealloying of the Cu-rich phase, whereas the microporosity is controlled by dissolving the Fe-rich phase, determined by both the initial Fe particle size and sintering profile. In addition to advancing the materials design method, the multiscale pore formation during dealloying was directly visualized and quantified via an interrupted in situ synchrotron X-ray nano-tomography. The 3D morphological analysis on tortuosity showed that the presence of the microporosity can compensate the increase of the diffusion path length due to nanoporosity, which facilitates diffusion within the porous structure. Altogether the focus of the work is to introduce a new strategy to design multiscale porous metals with enhanced transport properties, and sheds light on the fundamental mechanisms on the 3D morphological evolution of the system using advanced synchrotron X-ray nano-tomography for future materials development and applications.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Computational discovery of ultra-strong, stable, and lightweight refractory multi-principal element alloys. Part II: comprehensive ternary design and validation

Abstract Here the discovery of refractory multi-principal element alloys (MPEAs) with high-temperature strength and stability is pursued within a constrained and application-relevant design space. A comprehensive approach is developed and applied to explore all 165 ternary systems in the Al-Ce-Fe-Hf-Mo-Nb-Ta-Ti-V-W-Zr family. A subset of ternary systems that contain large areas in composition–temperature space with high strength and robust BCC phase stability is found. Twelve sets of high-performing alloys are identified, each set optimized for one combination of phase constraint, optimization target, and temperature range. Preliminary mechanical tests support the viability of the method. This work highlights the importance of considering phase stability, exploring non-equiatomic regions of composition space, and applying application-relevant constraints. Parts I and II provide three down-selection techniques for identifying high-performing BCC refractory MPEAs, design guidelines, and many candidates predicted to have BCC phase stability and strengths 2–3 times higher than any reported to date.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Challenges in computationally designing high temperature Fe-based austenitic alloys: Addressing the role of Ni additions

Alumina-forming austenitic (AFA) alloys are relatively inexpensive high performance materials which combine the creep resistance of low-cost austenitic alloys and the oxidation resistance of expensive alumina forming alloys. However, a fundamental understanding of the role of key alloying elements such as Ni, Cr, Al, Nb, Ti, V, B and C in the experimentally observed oxidation behavior of these alloys is still lacking. The present work is a first in a series of studies aiming to quantitatively describe the role of Ni in promoting or disrupting protective Al 2 O 3 scale formation on AFA alloys. Here, ternary Fe-Al-xNi model alloys with three different Ni contents were isothermally exposed in an atmosphere with a low partial pressure of oxygen between 800–1000 °C for 24 h to evaluate the role of Ni in the observed internal oxidation behavior. Increasing Ni contents had no impact on the internal oxidation behavior of the alloys. The experimental and theoretical analyses in the present work suggested a negligible effect of the internal oxide precipitates on the inward diffusion of oxygen, typically expected in these systems, while simultaneously highlighting the barriers in the development of reliable models for computation-assisted design of these alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Short-range order and its impact on the CrCoNi medium-entropy alloy

Traditional metallic alloys are mixtures of elements in which the atoms of minority species tend to be distributed randomly if they are below their solubility limit, or to form secondary phases if they are above it. The concept of multiple-principal-element alloys has recently expanded this view, as these materials are single-phase solid solutions of generally equiatomic mixtures of metallic elements. This group of materials has received much interest owing to their enhanced mechanical properties 1,2,3,4,5 . They are usually called medium-entropy alloys in ternary systems and high-entropy alloys in quaternary or quinary systems, alluding to their high degree of configurational entropy. However, the question has remained as to how random these solid solutions actually are, with the influence of short-range order being suggested in computational simulations but not seen experimentally 6,7 . In this paper we report the observation, using energy-filtered transmission electron microscopy, of structural features attributable to short-range order in the CrCoNi medium-entropy alloy. Increasing amounts of such order give rise to both higher stacking-fault energy and hardness. These findings suggest that the degree of local ordering at the nanometre scale can be tailored through thermomechanical processing, providing a new avenue for tuning the mechanical properties of medium- and high-entropy alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Critical cooling rates for amorphous-to-ordered complexion transitions in Cu-rich nanocrystalline alloys

Amorphous complexions in nanocrystalline metals have the potential to improve mechanical properties and radiation tolerance, as well as resistance to grain growth. In this study, the stability of amorphous complexions in binary and ternary Cu-based alloys is investigated by observing the effect of cooling rate from high temperature on the occurrence of amorphous-to-ordered complexion transitions. Bulk Cu-Zr and Cu-Zr-Hf alloy samples were annealed to induce boundary premelting and then quenched through a procedure that induces a gradient of local cooling rate through the sample height. Amorphous complexion thickness distributions were found to be invariant to local cooling rate in the Cu-Zr-Hf alloy, demonstrating enhanced stability of the amorphous complexion structure compared to the Cu-Zr alloy, which had thinner amorphous complexions in the regions that were slowly cooled. The experimental results are used to construct time-temperature-transformation diagrams for the amorphous-to-ordered complexion transition in both the binary and ternary alloys, enabling a deeper understanding of the influence of cooling rate and grain boundary chemistry on complexion transitions. In conclusion, the critical cooling rate necessary to avoid complexion transitions in the ternary alloy is found to be at least three orders of magnitude slower than that for the binary alloy.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Ternary PtIrNi Catalysts for Efficient Electrochemical Ammonia Oxidation

Due to high energy density, carbon-free feature, and easiness to be liquefied, ammonia (NH 3 ) has proved to be an effective alternative to hydrogen in low temperature fuel cells via its direct the ammonia oxidation reaction (AOR) for electricity generation. However, the kinetically sluggish AOR has prohibitively hindered the attractive direct ammonia fuel cell (DAFC) applications. Here we report an efficient AOR catalyst, in which ternary PtIrNi alloy nanoparticles well dispersed on a binary composite support consisting of porous silicon dioxide (SiO 2 ) and carboxyl-functionalized carbon nanotube (PtIrNi/SiO 2 -CNT-COOH) through a sonochemical-assisted synthesis strategy. The PtIrNi alloy nanoparticles, with the aid of abundant OHad provided by porous SiO 2 , and the improved electrical conductivity by CNTs, exhibit remarkable catalytic activity for the AOR in alkaline media. It is evidenced by a lower onset potential (~0.40 V vs. RHE) at room temperature, than that of commercial PtIr/C (ca. 0.43 V vs. RHE). Increasing NH 3 concentrations and operation temperatures significantly improve AOR performance of this catalyst. Specifically, AOR activity of the optimal PtIrNi nanoparticle catalyst can be significantly enhanced by elevating the temperature to 80ºC, with a much lower onset potential (~0.32 V vs. RHE), indicating that DAFC can be operated at higher temperature for increased performance. Constant-potential density functional theory (DFT) calculations showed that the Pt-Ir ensembles on {100}-terminated surfaces serve as the active site. Importantly, the introduction of Ni raises the center energy of the density of states projected onto the group d-orbitals of surface sites and thus lowers the theoretical onset potential for *NH 2 dehydrogenation to *NH when compared to Pt and Pt 3 Ir alloy.

25 ENERGY STORAGE↗
DOE OSTI2020

Primary solidification of ternary compounds in Al-rich Al–Ce–Mn alloys

Primary solidification of ternary compounds Al 20 Mn 2 Ce and Al 10 Mn 2 Ce were analyzed through the coupling of the thermodynamic modeling and classic nucleation theory. Thermodynamic models of Al 20 Mn 2 Ce and Al 10 Mn 2 Ce were developed using the CALPHAD approach based on first-principles calculated enthalpy of formation and experimental data obtained from this work and the literature. The analysis suggested that despite the larger thermodynamic driving force for nucleation of Al 10 Mn 2 Ce, nucleation is preferred for the Al 20 Mn 2 Ce phase in the highly undercooled liquid due to its smaller interfacial energy. Therefore, manufacturing methods with rapid cooling rates will favor primary solidification of Al 20 Mn 2 Ce for Al-rich Al–Ce–Mn alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Isolating intermediate Mg 11 Cu 6 Al 12 phase in ternary Mg-Cu-Al alloy by electrolytic dealloying

While dealloying is widely used to create nanoporous materials, it has rarely been employed to isolate difficult-to-synthesize intermediate phases. Here, in this work, we show how air-free, electrolytic dealloying at room temperature can be used to isolate the ternary intermetallic Mg 11 Cu 6 Al 12 phase. We create a ternary Mg-Cu-Al parent alloy containing the Mg 11 Cu 6 Al 12 compound and other phases, then subsequently remove these other phases via electrolytic dealloying to isolate the Mg 11 Cu 6 Al 12 phase. Isolated Mg 11 Cu 6 Al 12 phase exhibits ≈1 μm diameter rod-shaped microstructure. Phase and chemical analysis conducted using various techniques, including inductively coupled plasma and lab and synchrotron-based X-ray diffraction, show minimal impurities. This new approach to isolate the Mg 11 Cu 6 Al 12 phase can unlock its use in fundamental research and can be applied to other difficult-to-synthesize intermetallic compounds.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Designing for cooperative grain boundary segregation in multicomponent alloys

Tailoring the nanoscale distribution of chemical species at grain boundaries is a powerful method to dramatically influence the properties of polycrystalline materials. However, classical approaches to the problem have tacitly assumed that only competition is possible between solute species. In this paper, we show that solute elements can cooperate in the way they segregate to grain boundaries: In properly targeted alloys, the different chemical species cooperate to each fill complementary grain boundary sites disfavored by the other. By developing a theoretical “spectral” approach to this problem based on quantum-accurate grain boundary site distributions, we show how grain boundaries can be cooperatively alloyed, whether by depletion or enrichment. We provide machine-learned cosegregation information for over 700 ternary aluminum-based alloys and experimentally validate the concept in one ternary alloy where cosegregation is not expected by prior models but is expected based on the cooperative model.

grain boundaries↗
DOE OSTI2020

Design of super-strong and thermally stable nanotwinned Al alloys via solute synergy

Al alloys have widespread industrial applications. However, their mechanical strength is often much lower than steels. Here, we investigate the influence of solutes on achieving ultrahigh strength and thermal stability of nanotwinned Al alloys. In situ micropillar compression tests show the addition of a small amount of Ti can significantly increase the mechanical strength of Al–Ni alloys to 2 GPa. Deformation induced detwinning, Ni segregation and grain coarsening as discovered in binary Al–Ni alloys are mostly absent in the ternary Al–Ni–Ti alloys. Moreover, the ternary Al–Ni–Ti alloys have outstanding thermal stability. Density function theory calculations reveal the synergetic pinning effect of Ni–Ti solute pairs on incoherent twin boundaries. This study demonstrates that the proper selection of synergistic solute pairs is critical to improve the thermal stability and mechanical properties of nanotwinned Al alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Emulation of neutron-irradiated microstructure of austenitic 21Cr32Ni model alloy using dual-ion irradiation

Here, in this study, the capability of heavy-ion irradiation to emulate neutron irradiation was demonstrated on an austenitic 21Cr32Ni type ternary model alloy. The model alloy used in this study is chemically analogous but compositionally simpler than of alloy 800H, which is a candidate austenitic Ni alloy which has been proposed for use in Generation IV reactors. The microstructure of the 21Cr32Ni model alloy irradiated in the BOR-60 fast reactor to 17.1 dpa and 35 dpa at ~380°C was characterized using transmission electron microscopy (TEM). The 17.1 dpa BOR-60 irradiated microstructure was then compared with the microstructure of the same material developed under dual-ion (DI) irradiation using various He/dpa ratios between 0.1 and 16.6 appm He/dpa in the temperature range of 430°C-500°C. The results showed that both neutron and DI irradiation of 21Cr32Ni model alloy produced dislocations in the form of a dislocation network as well as {111}-type faulted dislocation loops, cavities, and radiation-induced Ni enrichment at radiation-induced sinks. When the dose and the He/dpa ratio were kept similar to those in neutron irradiation, DI irradiation of the 21Cr32Ni model alloy at 460°C resulted in over-nucleation of small cavities and in a high density of faulted dislocation loops compared to those observed in the fast-neutron irradiated alloy of the same heat irradiated at ~380°C. The optimal condition for reproducing the neutron-irradiated microstructure was DI irradiation at 460°C and 0.1 appm He/dpa. In that case, the faulted loop and cavity size distributions in the BOR-60 irradiated 21Cr32Ni model alloy samples closely matched with those measured in the DI irradiated 21Cr32Ni model alloy sample. The fact that the He/dpa is an order of magnitude smaller than the helium generation rate for fast neutron irradiation, stops over nucleation and allows for the development of a similar microstructure as for neutron irradiation.

21Cr32Ni model alloy↗
DOE OSTI2024

Hypereutectic Al-Ce-X (X=Mn, Cr, V, Mo, W) alloys fabricated by laser powder-bed fusion

Here, we characterize the microstructures and high-temperature mechanical properties of Al-2Ce and ternary Al-2Ce-1X (at.%) alloys fabricated by laser powder-bed fusion (LPBF), where X = Mn, Cr, V, Mo, and W are slow-diffusing transition metals. All ternary alloys show a hypereutectic microstructure in the as-LPBF state, containing an interconnected network of eutectic Al 11 Ce 3 phases (~10 vol.%) and an additional population of submicron, equiaxed Al 20 CeX 2 primary precipitates (~10 vol.%) which are isomorphous among these five alloys. Similar microstructures are present in arc-melted rods and atomized powders but are coarser due to the slower cooling rates in these processes. The hardness of the as-LPBF ternary Al-Ce-X alloys (1300–1400 MPa) is higher than that of the binary Al-Ce alloy (~1100 MPa) due to the higher volume fraction of strengthening phases. Furthermore, during exposure at 400 °C for up to three months, greater hardness retention is achieved in the ternary Al-Ce-X alloys (65–75%) than in the binary Al-Ce alloy (~55%), which is attributed to the extreme coarsening resistance of the Al 20 CeX 2 precipitates imparted by the very slow-diffusing ternary solute. These coarsening-resistant Al 20 CeX 2 precipitates also substantially improve alloy creep resistance, increasing the threshold stress for dislocation creep at 300°C from ~32 MPa for the binary Al-Ce alloy to ~77–100 MPa for the ternary Al-Ce-X alloys, and at 400°C from <10 MPa for the binary Al-Ce alloy to >40 MPa for the ternary Al-Ce-V alloy.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Bulk nanocrystalline Al alloys with hierarchical reinforcement structures via grain boundary segregation and complexion formation

Grain size engineering, particularly reducing grain size into the nanocrystalline regime, offers a promising pathway to further improve the strength-to-weight ratio of Al alloys. Unfortunately, the fabrication of nanocrystalline metals often requires non-equilibrium processing routes, which typically limit the specimen size and require large energy budgets. In this study, multiple dopant elements in ternary Al alloys are deliberately selected to enable segregation to the grain boundary region and promote the formation of amorphous complexions. Three different fully dense bulk nanocrystalline Al alloys (Al-Mg-Y, Al-Fe-Y, and Al-Ni-Y) with small grain sizes were successfully fabricated using a simple powder metallurgy approach, with full densification connected directly to the onset of amorphous complexion formation. All the compositions demonstrate densities above 99% with grain sizes <60 nm following consolidation via hot pressing at 585 °C. The very fine grain structure results in excellent mechanical properties, as evidenced by nanoindentation hardness values in the range of 2.2-2.8 GPa. Detailed microstructural characterization verifies the segregation of all dopant species to grain boundaries as well as the formation of amorphous complexions, which suggests their influential role in aiding effective consolidation and endowing thermal stability in the alloys. Moreover, nanorods with a core-shell structure are also observed at the grain boundaries, which likely contribute to the stabilization of the grain structure while also strengthening the materials. Lastly, intermetallic particles with sizes of hundreds of nanometers form in all systems. As a whole, the results presented here demonstrate a general alloy design strategy of segregation and boundary evolution pathway that enables the fabrication of multiple nanocrystalline Al alloys with hierarchical microstructures and improved performance.

36 MATERIALS SCIENCE↗
DOE OSTI2023

High throughput discovery of ternary Cu-Fe-Ru alloy catalysts for photo-driven hydrogen production

Light driven hydrogen production from the water splitting reaction has the ability to reduce dependence on fossil fuels in a green energy future. Here, we highlight the discovery of Cu x Ru y Fe 1-x-y nanoparticle catalysts for photo-driven hydrogen production. Through a high throughput experimental setup, robust data management pipelines and intentional experimental design, this study uncovered three highly active bimetallic systems for photo-driven hydrogen and identified a new trimetallic catalyst for this system. In most cases, the multimetallic catalysts outperformed the monometallics. Furthermore, this study highlights the expansive catalytic screening capabilities of this system in contrast to traditional catalytic selection processes through the discovery of distributions of particle compositions in binary and ternary mixtures of metals with high activity for hydrogen evolution.

08 HYDROGEN↗
DOE OSTI2022

Elastic behavior of binary and ternary refractory multi-principal-element alloys

Elastic properties are essential to the mechanical performance of materials, and therefore, can be tuned to design high-performance materials. In this study, the elastic constants of the equiatomic ternary refractory multi-principal-element alloys, NbTiV, and MoNbV, were investigated, using in-situ neutron diffraction and first-principles calculations. The experimentally measured and theoretically predicted elastic constants show a good agreement. The alloying effect of adding Ti and Mo into NbV base alloy on the elastic constants is studied. Particularly, adding Ti elements into the NbV alloy results in the increase of the Zener anisotropy ratio from 0.59 to 0.99, leading to the formation of the elastically isotropic NbTiV alloy, while the addition of Mo decreases the anisotropy ratio to 0.52. Pugh’s ratio (B/G), Cauchy pressure (C 12 -C 44 ), and Poisson’s ratio (ν) are used to predict the brittle/ductile nature of the studied alloys, which is consistent with the mechanical results. The present work provides valuable insights into the design of ductile and strong refractory high-entropy alloys by tuning the elastic properties.

36 MATERIALS SCIENCE↗