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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 OSTI2024

Electrical property enhancement of non-heat-treatable wrought aluminum alloys using graphene additives

With growing efforts of electrification, aluminum’s role as a light-weight conductor material has become increasingly prominent. There is a critical need to improve the electrical performance of aluminum at room temperature and high operating temperatures. In this study, the effect of graphene nanoparticle additives on the electrical performance of a non-heat treatable alloy were (AA3003) explored. Graphene’s unusual structure and electronic properties were used to improve AA3003 properties. Here, in this work, the effects of graphene on the evolution of electrical properties and microstructural features have been explored on lab scale hot extruded AA3003-graphene composites. Hot pressing schedules and extrusion temperatures were varied to investigate changes in intermetallic dispersion characteristics in the presence of dispersed graphene. We measured a reduction of 10.3 % in the temperature coefficient of resistance in the AA3003 sample with 0.05 wt% graphene extruded at 400 °C, along with a maximum increase of 1.1 % in electrical conductivity at 20 °C. Increasing the hot-pressing times up to 8 hours was also found to consistently increase the electrical conductivity, due to increased precipitation of intermetallic phases. Despite being a non-heat treatable alloy, AA3003 displays interesting precipitation dynamics and grain recrystallization trends that can be modulated with varying levels of heat treatment, graphene concentrations, and hot extrusion process parameters.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Microstructural characterization of phase-separated co-deposited Cu–Ta immiscible alloy thin films

Elevated temperature co-sputtering of immiscible elements ends in a variety of self-organized morphologies due to phase separation. Cu–Ta is used as a model system to understand the evolution of phase-separated microstructural morphologies by co-sputtering thin films with nominal 50–50 at.% composition at four temperatures: 25, 400, 600, and 800 °C. Scanning/transmission electron microscopy of the film cross sections showed the microstructure morphology varied from nanocrystalline Cu–Ta at 25 °C to a wavy ribbon-like structure at 400 °C, to Cu-rich agglomerates surrounded by Ta-rich veins at 600 and 800 °C. In the agglomerate-vein morphology, microstructural features were present on two length scales, from a few nanometers to a few tens of nanometers, thus making the structures hierarchical. On the nanoscale, the Cu-rich agglomerates contained Ta precipitates, whereas the Ta-rich veins had embedded Cu nanocrystals. The various microstructures can be attributed to the highly disparate constituent element interdiffusion at the deposition temperatures with the Cu having orders of magnitude higher mobility than Ta at the deposition temperatures. This research of processing–microstructure relationship will be useful in guiding the design of hierarchical multiphase microstructures in binary or multicomponent thin films with tailored mechanical properties.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Deformation Mechanism Transition in Additively Manufactured Compositionally Graded Fe-Base Alloys

Microstructure-dependent deformation and fracture behavior was investigated for an additively manufactured compositionally graded alloy (CGA) printed using the laser-directed energy deposition (L-DED) method to explore an alternative approach for dissimilar metal joints in nuclear energy systems. The electron backscatter diffraction (EBSD) maps from scanning electron microscopy (SEM) display a clear microstructural transition with decreasing austenite-forming elements (Ni and Mn), from an austenite (γ) dominant structure, to a complex composite structure containing ferrite (α), martensite (α') and retained austenite, and then to a fully ferritic structure. EBSD data were recorded in situ during tensile testing in SEM, and the evolution of the deformation mechanism and microstructure was characterized using Kikuchi diffraction pattern analysis. Complementary analysis for high-resolution features was also performed using scanning transmission electron microscopy (STEM). The Ni/Mn-rich austenite-dominant microstructures showed a complex deformation mechanism of two-step martensitic transformation (γ→ε→α'), whereas the minor austenite phase retained in the ferrite and/or martensite matrix showed a single transformation route (γ→α'). Ordinary dislocation glide and twinning via partial dislocation glide were observed in the austenite deformation. Meanwhile, the ferrite and martensite grains deformed mainly by ordinary dislocation slips and grain rotation. Furthermore, static tensile fracture was also highly dependent on local composition and phase constituents.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Additive manufacturing of a metastable high entropy alloy: Metastability engineered microstructural control via process variable driven elemental segregation

Compositional paradigm shift in high entropy alloys (HEAs) provided new opportunities for microstructural engineering, whereas process control during laser powder bed fusion (LPBF) additive manufacturing (AM) enable fine microstructure tailoring. Metastability engineering in transformation induced plasticity (TRIP) HEAs by addition of minor alloying elements is an attractive strategy for fine microstructural tuning. This study explored in detail the microstructural evolution during LPBF AM of a metastable Fe 40 Mn 20 Co 20 Cr 15 Si 5 (at.%) dual phase HEA (CS-HEA). LPBF processing window for CS-HEA was established based on quantitative analysis and experiments. Based on melt pool overlap lack of fusion pores were observed at lower energy densities (J) of $\textit{J}$ ≤ 31.25 J/mm 3 and key-hole formation by melt pool destabilization in case of $\textit{J}$ ≥ 75 J/mm 3 . The microstructure of CS-HEA consists of metastable FCC-γ and HCP-ε phases; LPBF process parameters governed the final phase fraction in the alloy which has been correlated to metastability alteration of the high temperature γ phase. Final microstructural engineering was devised by LPBF process control which enabled cooling rate manipulation to guide Mn and Si segregation at the cell boundaries, thereby controlling the matrix metastability and final phase fraction. Additionally, high resolution transmission electron microscopy (TEM) revealed disparity in stacking fault morphology in CS-HEA with LPBF process variable alterations associated with local variations in chemical composition and stacking fault energy. Further, the phase evolution with process parameters also affected the nanomechanical behavior of the alloy.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Impact of Processing on Structural and Compositional Evolution in Mixed Metal Halide Perovskites during Film Formation

Understanding crystallization processes and their pathways in metal-halide perovskites is of crucial importance as this strongly affects the film microstructure, its stability, and device performance. While many approaches are developed to control perovskite formation, the mechanisms of film formation are still poorly known. Using time-resolved in situ grazing incidence wideangle X-ray scattering, the film formation of perovskites is investigated with average stoichiometry Cs 0.15 FA 0.85 PbI 3 , where FA is formamidinium, using the popular antisolvent dropping and gas jet treatments and this is contrasted with untreated films. i) The crystallization pathways during spin coating, ii) the subsequent postdeposition thermal annealing, and iii) crystallization during blade coating are studied. The findings reveal that the formation of a nonperovskite FAPbI 3 phase during spin coating is initially dominant regardless of the processing and that the processing treatment (e.g., antisolvent dropping, gas jet) has a significant impact on the as-cast film structure and affects the phase evolution during subsequent thermal treatment. It is shown that blade coating can be used to overcome the nonperovskite phase formation via solvothermal direct crystallization of perovskite phase. This work shows how real-time investigation of perovskite formation can help to establish processing–microstructure–functionality relationships.

36 MATERIALS SCIENCE↗
DOE OSTI2024

In-situ synchrotron X-ray diffraction of hydroxyapatite-zirconia composite during conventional and flash sintering

Here, we conducted in-situ X-ray diffraction to study the crystalline phase evolution in hydroxyapatite-zirconia composites during both conventional and flash sintering processes. Additionally, we examined the thermal history and microstructure of the composite under these sintering conditions. Despite both sintering methods reaching similar average temperatures, they yielded distinct results in terms of crystalline phase composition and microstructure. In the flash sintered samples, we observed a complete transformation of hydroxyapatite into α- tricalcium phosphate and a complete tetragonal to cubic phase transition in zirconia. Conversely, the conventionally sintered samples remained practically stable. Notably, the flash sintered samples exhibited needle-like microstructures, which were absent in their conventionally sintered counterparts. This divergence suggests that the application of an electric field plays a role in generating athermal effects during the sintering of hydroxyapatite-zirconia composites.

36 MATERIALS SCIENCE↗
DOE OSTI2021

The onset of alloying in Cu-Ni powders under high-shear consolidation

Friction consolidation (FC) is a solid phase processing methodology that densifies a material through high-shear deformation and pressure at elevated temperature. The method has garnered interest in the scientific community because of its ability to produce extremely refined and homogeneous microstructures, off-axis texture development, and improved material properties. This manuscript presents an investigation of Cu and Ni material mixing via evaluation of morphological evolution, grain boundary characterization, and compositional analysis to provide insights on the operational alloying mechanisms occurring under high shear and elevated temperature. Using correlative microscopy techniques, we show alloying progresses via a combination of grain boundary diffusion and interfacial roughening at heterophane boundaries. Evidence supporting Cu infiltration along Ni-Ni grain boundaries along with asymmetric diffusion of Cu into Ni grains is highlighted. The resultant, consolidated microstructure was produced directly from a powder compact in ~30 s and exhibited a submicron, equiaxed grain size.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Compositionally-Driven Formation Mechanism of Hierarchical Morphologies in Co-Deposited Immiscible Alloy Thin Films

Co-deposited, immiscible alloy systems form hierarchical microstructures under specific deposition conditions that accentuate the difference in constituent element mobility. The mechanism leading to the formation of these unique hierarchical morphologies during the deposition process is difficult to identify, since the characterization of these microstructures is typically carried out post-deposition. We employ phase-field modeling to study the evolution of microstructures during deposition combined with microscopy characterization of experimentally deposited thin films to reveal the origin of the formation mechanism of hierarchical morphologies in co-deposited, immiscible alloy thin films. Our results trace this back to the significant influence of a local compositional driving force that occurs near the surface of the growing thin film. We show that local variations in the concentration of the vapor phase near the surface, resulting in nuclei (i.e., a cluster of atoms) on the film’s surface with an inhomogeneous composition, can trigger the simultaneous evolution of multiple concentration modulations across multiple length scales, leading to hierarchical morphologies. We show that locally, the concentration must be above a certain threshold value in order to generate distinct hierarchical morphologies in a single domain.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Microstructural, Oxidation, and Mechanical Behavior of NbTi-Based Refractory Alloys with 5 to 10 Pct Co, Cr, and Ni Additions

NbTi-based refractory alloys with additions of Co, Cr, and Ni represent an interesting medium-entropy alloy system with potential for protective oxide film formation, high strength, and ductility. This study investigates the microstructural evolution, oxidation behavior, and mechanical properties of NbTi-based alloys containing 5 to 10 at. pct Co, Cr, and Ni. CALPHAD predictions suggest that this composition range can be heat treated to obtain a predominantly body-centered cubic matrix phase. Mechanical properties, including microhardness, yield strength, maximum strength, and specific strength are evaluated through isothermal compression tests conducted between room temperature and 800 °C. The oxidation kinetics of these alloys are assessed through discontinuous oxidation tests. Parabolic oxidation kinetics were observed for NbTi–10Ni and NbTi–5Co, while linear oxidation kinetics were found for NbTi–10Cr and NbTi–10(CoCrNi). Microstructures and oxide layers are characterized using X-ray diffraction, electron backscatter diffraction, energy-dispersive X-ray spectroscopy, and scanning electron microscopy. All alloys exhibit significant mechanical softening between room temperature and 800 °C, with elastic-perfectly plastic flow observed at 800 °C. The addition of 10 pct Cr to NbTi resulted in two BCC phases up to 1050 °C, conflicting with CALPHAD predictions of a single-phase solid solution at this temperature, and resulting in higher flow stress at 800 °C. NbTi–10(CoCrNi) exhibited the lowest flow stress at 800 °C despite having more ‘cocktail effect’ potential and insufficient molar fractions of Co, Cr, or Ni to form a desirable protective oxide film.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Understanding and Strategies for Controlled Interfacial Phenomena in Lithium-Ion Batteries and Beyond

Electrolyte chemistry and properties and electrode structure and chemical properties particularly at the interfaces are crucial for the development of advanced battery components. This project focused on elucidating the roles of the electrolyte and electrode on the formation and evolution of the SEI layer and cell electrochemical performance on silicon and on Li metal anodes. For Si nano/microstructures we evaluated lithiation, volume changes, reactivity, and chemo-mechanical transformations as functions of nanoparticle size, shape, presence of coatings, electrolyte composition, electron leakage to the electrolyte, and cycling. For Li metal anodes we provided detailed analyses of the electrode and electrolyte effects on interfacial reactivity and as a function of microstructural evolution and underlying stochasticity as dendrites nucleate and grow. We thoroughly investigated and simulated how the chemistry of the various components of the electrolyte and the electrode architecture may affect the electrochemical reactions as well as cell degradation. A multiscale modeling approach was utilized, where atomistic simulations informed about the microscopic behavior of the system, and intermediate time and length scales were investigated with mesoscopic models. Results were also tested against selected experiments from our collaborators. The combined theoretical-experimental strategy saves costs by utilizing predictions from computational analyses to guide experimentation.

25 ENERGY STORAGE↗
DOE OSTI2024

Refining Microstructures in Additively Manufactured Al/Cu Gradients Through TiB 2 Inclusions

Here, the additive manufacture of compositionally graded Al/Cu parts by laser engineered net shaping (LENS) is demonstrated. The use of a blue light build laser enabled deposition on a Cu substrate. The thermal gradient and rapid solidification inherent to selective laser melting enabled mass transport of Cu up to 4 mm from a Cu substrate through a pure Al deposition, providing a means of producing gradients with finer step sizes than the printed layer thicknesses. Divorcing gradient continuity from layer or particle size makes LENS a potentially enabling technology for the manufacture of graded density impactors for ramp compression experiments. Printing graded structures with pure Al, however, was prevented by the growth of Al 2 Cu 3 dendrites and acicular grains amid a matrix of Al 2 Cu. A combination of adding TiB 2 grain refining powder and actively varying print layer composition suppressed the dendritic growth mode and produced an equiaxed microstructure in a compositionally graded part. Material phase was characterized for crystal structure and nanoindentation hardness to enable a discussion of phase evolution in the rapidly solidifying melt pool of a LENS print.

36 MATERIALS SCIENCE↗
DOE OSTI2020

The effects of introducing elasticity using different interpolation schemes to the grand potential phase field model

Introducing elastic energy in the phase field method has been shown to influence interfacial energy, depending on the elastic interpolation scheme. This study investigates the impact of the elastic energy when using a grand potential-based phase field method, comparing the result of Khachaturyan’s strain interpolation scheme (KHS) and Voight-Taylor’s elastic energy interpolation scheme (VTS). The KHS model leads to a decrease in the interfacial energy, while the VTS model leads to an increase. The change in interfacial energy is greater with the VTS model than the KHS model, which suggests that the KHS model is more appropriate to limit the artificial impact of the elastic energy on the interfacial energy. When the contribution at the interface is not negligible, it is shown that both the microstructure evolution kinetics and the equilibrium microstructure can be influenced by the choice of the elastic scheme being used. In addition, this paper shows that the grand potential model might not be appropriate when the system requires the introduction of a composition-dependent term in the elastic energy contribution. This limitation is due to the need for an explicit and invertible relation between the total potential and the composition.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Deep learning-based segmentation of lithium-ion battery microstructures enhanced by artificially generated electrodes

Accurate 3D representations of lithium-ion battery electrodes, in which the active particles, binder and pore phases are distinguished and labeled, can assist in understanding and ultimately improving battery performance. Here, we demonstrate a methodology for using deep-learning tools to achieve reliable segmentations of volumetric images of electrodes on which standard segmentation approaches fail due to insufficient contrast. We implement the 3D U-Net architecture for segmentation, and, to overcome the limitations of training data obtained experimentally through imaging, we show how synthetic learning data, consisting of realistic artificial electrode structures and their tomographic reconstructions, can be generated and used to enhance network performance. We apply our method to segment x-ray tomographic microscopy images of graphite-silicon composite electrodes and show it is accurate across standard metrics. We then apply it to obtain a statistically meaningful analysis of the microstructural evolution of the carbon-black and binder domain during battery operation.

25 ENERGY STORAGE↗
DOE OSTI2019

Atom Probe Tomography for understanding microstructural and chemical changes in nuclear materials

Atom Probe Tomography (APT) is routinely employed to determine 3D microstructure and chemistry changes in structural materials used in reactor to understand irradiation effect. These findings help to correlate changes to mechanical and physical properties of nuclear materials which are subjected to extreme reactor conditions. With safety and economics of a reactor in mind, it is essential to be able to predict the changes in the fuel composition and microstructure as a function of burnup. Also, there is current need to develop advanced fuels with improved properties and performance which requires the experimental data on changes in microstructure, physical and chemical properties after irradiation for feedback process. A novel approach is presented to determine the local burnup in irradiated fuels using isotopic quantification obtained by Atom Probe Tomography (APT). Considering the volume of sample used (<100?µm3) for APT experiments using the lift-out process in a scanning electron microscope equipped with a Focused Ion Beam (FIB), the presented method determines the local burnup from a nuclear fuel, where a minimal amount of waste is produced. In this work, three samples were analyzed with different burnup conditions to quantify the isotopes of 235U, 236U, and 238U for burnup calculation in the irradiated metallic U–7Mo dispersion fuel. The calculated values were found in excellent agreement with MCNP calculations. With regard to structural materials, one of the primary factors limiting the utilization of fuel rods of Zr alloys is hydrogen pick up during oxidation. Past experimental studies have shown that the hydrogen pickup in Zirconium alloys is influenced by the alloy composition as well by irradiation temperature and neutron dose. Oftentimes, it is not feasible to carry out comprehensive studies on understanding the microstructural evolution in neutron irradiated materials since in reactor irradiation programs are extremely costly, lengthy and logistically complicated. The use of ion irradiation as a substitute has grown in recent years for several reasons including less radioactivity, faster irradiations and lower costs. In the framework of the MUZIC 3 project, samples of Zircaloy-4 have been proton and Zr2+ irradiated at the Michigan Ion Beam Lab (MIBL) facility with aim to create a microstructure that is similar to that observed after in-reactor service. The temperature of the environment is adjusted to compensate for the higher dose rate, as has been done previously. As a first step in this project the irradiated microstructures have been characterized using Transmission Electron Microscopy and Atom Probe Tomography to elucidate the microstructural changes, including precipitate amorphization and dissolution and the formation of dislocation loops. This presentation plans to highlight initial finding of this project.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Phase-field modeling of radiation-induced composition redistribution: An application to additively manufactured austenitic Fe–Cr–Ni

Multicomponent alloys undergoing irradiation damage develop radiation-induced composition redistribution at point defect sinks such as grain boundaries (GBs) and dislocations. Such redistribution results in undesired changes to their mechanical behavior and corrosion resistance. Additively manufactured alloys proposed for future nuclear applications are expected to demonstrate a distinct response to irradiation owing to their unique microstructure with as-solidified dislocation density and chemical microsegregation. To capture the composition redistribution in such systems, we develop a mesoscale model with coupled evolution of atomic and point defect components in the presence of dislocation density, dislocation heterogeneity, and thermodynamic interactions at the GB. The model is parameterized for an FCC Fe–Cr–Ni alloy as a representative system for austenitic stainless steels, and simulations are performed in 1D and 2D as a function of irradiation temperature, dose, dislocation density, and grain size. Radiation-induced segregation (RIS) characterized by Cr depletion and Ni enrichment is predicted at both the GB and the dislocation cell wall, with RIS being lower in magnitude but wider at the cell wall. Strongly biased absorption of self-interstitials by dislocations is found to suppress Ni enrichment but slightly enhance Cr depletion under certain conditions. Thermodynamic segregation at the GB is predicted to be narrower and opposite in sign to RIS for both Cr and Ni. Importantly, non-monotonic segregation is found to occur when both thermodynamic and RIS mechanisms are considered, providing a novel physical interpretation of experimental observations. The model is expected to serve as a key tool in accelerated qualification of irradiated materials.

additively manufactured microstructure↗
DOE OSTI2022

Electrochemical Control of the Morphology and Functional Properties of Hierarchically Structured, Dendritic Cu Surfaces

Electrodeposited dendritic copper foams have been extensively studied as an electrocatalyst for CO 2 reduction reaction (CO 2 RR). Many parameters, such as dendrite size, porosity, pore size, and crystal faceting, define the hierarchical properties of these structures and their subsequent bubble evolution and CO 2 RR capabilities. Herein, the effects the electrodeposition conditions (potential, pH) have on the resulting crystallinity, microstructure, and macroporosity of the copper foam are studied. These morphological differences and the corresponding effects on electrocatalytic activity are characterized. It is shown that the composition of the electrodeposition bath can have significant effects on the mechanics of bubble formation and detachment at the surface during hydrogen evolution reaction in acidic solutions. Similarly, the electrodeposition conditions for the synthesis of the foam affect the product selectivity during CO 2 RR electrocatalysis. As a result, foams deposited in alkaline electrodeposition solutions show high faradaic efficiency and specificity toward C 2 H 6 , an uncommon product of CO 2 RR, at modest applied potentials (−0.8 V versus reversible hydrogen electrode.

14 SOLAR ENERGY↗
DOE OSTI2021

Early reactivity of sodium silicate-activated slag pastes and its impact on rheological properties

The fast loss of fluidity of sodium silicate-activated slag (SS-AAS) systems have been widely studied in the literature. In this study, the rheology of these cements has been correlated with the evolution of the reaction products formed over time. For this purpose, a combination of experimental characterization techniques, to study the pore solution composition and microstructure of SS-AAS pastes and thermodynamic calculations have been applied. The initial precipitation of ill-defined N-A-S-H and C-N-A-S-H producta leads to a fast increase of the storage modulus after 40 min of reaction. These products are formed from the reaction of the Na{sup +} ions and silicate ions of the activator with the Ca{sup 2+} and aluminate species dissolved from the slag. However, when a shear is applied, the structure breaks down and fluidity is recovered, that infers that the attractive forces between the particles are low at the early stages of hydration.

36 MATERIALS SCIENCE↗
DOE OSTI2022

An Overview of Nano Multilayers as Model Systems for Developing Nanoscale Microstructures

The microstructural transformations of binary nanometallic multilayers (NMMs) to equiaxed nanostructured materials were explored by characterizing a variety of nanoscale multilayer films. Four material systems of multilayer films, Hf-Ti, Ta-Hf, W-Cr, and Mo-Au, were synthesized by magnetron sputtering, heat treated at 1000 °C, and subsequently characterized by transmission electron microscopy. Binary systems were selected based on thermodynamic models predicting stable nanograin formation with similar global compositions around 20–30 at.%. All NMMs maintained nanocrystalline grain sizes after evolution into an equiaxed structure, where the systems with highly mobile incoherent interfaces or higher energy interfaces showed a more significant increase in grain size. Furthermore, varying segregation behaviors were observed, including grain boundary (GB) segregation, precipitation, and intermetallic formation depending on the material system selected. The pathway to tailored microstructures was found to be governed by key mechanisms and factors as determined by a film’s initial characteristics, including global and local composition, interface energy, layer structure, and material selection. This work presents a global evaluation of NMM systems and demonstrates their utility as foundation materials to promote tailored nanomaterials.

Appleget, Chelsea D.↗