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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Microstructure and Properties of AlCoCrFeNiTi High-Entropy Alloy Coating on AISI1045 Steel Fabricated by Laser Cladding

AISI1045 steel is widely used in mechanical engineering. In spite of the favorable toughness and strength, the surface properties of AISI1045 steel, such as hardness, wear resistance and corrosion resistance, are not ideal. Therefore, surface modification of AISI1045 is necessary, especially for the parts suffering severe work condition. Laser cladding is a promising surface modification technology. In this work, the AlCoCrFeNiTi high-entropy alloy (HEA) coatings were prepared on the AISI1045 steel to improve its surface properties. Metallurgical bonding is obtained between the coating and the substrate. The microstructure and surface properties of the coating were characterized by scanning electron microscope, energy-dispersive spectrometry, x-ray diffraction, electrochemical workstation, microhardness tester and pin-on-ring wear tester. The microstructure of the coating produced by laser cladding is dendritic. The AlCoCrFeNiTi HEA coating is mainly composed of disordered body-centered cubic phase (Fe-Cr), ordered B2 phase (AlNi) and intermetallic phase (Ti-rich). The coating shows excellent abrasion resistance and corrosion resistance in comparison with the substrate. The maximum microhardness of the coating reaches approximately 865 HV, which is 4.5 times of AISI1045 steel.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Microstructural and Property Evolution of Continuous Columnar-Grained Polycrystalline Copper during Extreme Plastic Deformation at Room Temperature

An extreme extensibility with a true strain of 11.12 has been obtained for continuous columnar-grained (CCG) polycrystalline copper at room temperature, which was cold-drawn from a 10-mm-diameter as-cast rod into a 38.5-μm-diameter ultra-fine wire without any intermediate softening heat treatment. During the extreme plastic deformation, the ultimate tensile stress increased from 140 MPa for as-cast CCG copper to 525 MPa for the deformed sample at a true stain of 11.12, while the relative electrical conductivity maintained a high value of 97.6% IACS. On this basis, CCG copper is an excellent raw material for the fabrication of ultra-fine wires with both high strength and high electrical conductivity. The original columnar grains experienced grain subdivision and formed fibrous grains along the drawing direction with a fibrous longitudinal morphology and curly transverse microstructure at medium to high strain. The subdivision of the fibrous grains then went on as the extreme plastic deformation continued. Large amounts of strain-induced boundaries and microstructural refinement facilitated the storage of abundant glide dislocations created by extreme plastic deformation. Thus, extreme plastic extensibility can be achieved through continuous work hardening of CCG copper.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Ti Modification on Microstructures and Properties of Carbidic Austempered Ductile Iron

In this paper, we investigated the effect of titanium modification on microstructures and properties of carbidic austempered ductile iron (CADI) containing 3.72 wt.% C, 2.77 wt.% Si, and 0.51 wt.% Mn. The results showed that with the addition of 0.1 wt.% Ti, TiC particles were formed, and distributed in carbides and matrix. Microstructural observation indicated that the maximum diameter of graphite nodules decreased from 58 to 40 μm, and the shape of carbides transformed from network to fragmentation, which was related to the nucleation of the eutectic structure (γ + (Fe, Cr){sub 3}C) where TiC particles act as the nucleus. After isothermal quenching at 300 °C, the hardness of Ti-bearing CADI was 3.5 HRC higher than ordinary CADI, and the impact toughness was increased by 14.3%. Additionally, due to the decrease in exfoliation, the wear loss of Ti-bearing CADI was 14.8% lower than ordinary CADI during the block-on-ring wear test at the surface load of 300 N.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Microstructure and Wear Performance of Cobalt-Containing Iron-Based Slag-Free Self-shielded Flux-Cored Wire

A new type of cobalt-containing iron-based slag-free self-shielded flux-cored wire was developed for hardfacing. The influence of cobalt additions on the microstructure and wear performance of the hardfacing was investigated. The cobalt-containing iron-based hardfacing alloy has a typical hypereutectic microstructure consisting of primary M{sub 7}(C, B){sub 3} carbide, and a eutectic of M{sub 3}(C, B) carbide and austenite (part of which subsequently transformed into martensite). Cobalt promoted the formation of austenite and changed the morphology of the primary carbide and eutectic colonies. The morphology of primary carbide became fragmented with increasing cobalt due to the possible impeding effect of cobalt to the movement of the M{sub 7}(C, B){sub 3}/liquid interface. Different structures of the eutectic carbides were observed—the chrysanthemum structure for 1.42 wt.% cobalt, the skeleton form for 2.88 wt.% cobalt, the radial stripe 4.37 wt.% cobalt and the discrete stripe for 5.75 wt.% cobalt. Wear loss of the hardfacing alloy containing 2.88 wt.% cobalt was the smallest among all the alloys, owing to the large primary large carbide and skeleton-shaped eutectic carbides, the proper amount of austenite phase separating the M{sub 7}(C, B){sub 3} and M{sub 3}(C, B) carbides, the solid solution strengthening by cobalt in the matrix, and the high hardness of the alloy. Moreover, the wear resistance has a tendency to decrease with the increase in velocity as well as load.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Microstructure and Mechanical Properties of a Multiphase FeCrCuMnNi High-Entropy Alloy

A FeCrCuMnNi high-entropy alloy was produced using vacuum induction melting, starting from high-purity raw materials. The microstructure and mechanical properties of the as-cast FeCrCuMnNi alloy were studied, considering x-ray diffraction (XRD), scanning electron microscopy, and hardness and tensile tests. XRD results revealed the existence of two FCC phases and one BCC phase. Microstructural evaluation illustrated that the as-cast alloy has a typical cast dendritic structure, where dendrite regions (BCC) were enriched in Cr and Fe. Interdendritic regions were saturated with Cu and Ni and revealed G/B(T) {110} 〈111〉 and Brass {110} 〈112〉 as the major texture components. The produced alloy revealed an excellent compromise in mechanical properties due to the mixture of solid solution phases with different structures: 300 HV hardness, 950 MPa ultimate tensile strength and 14% elongation. Microhardness test results also revealed that the BCC phase was the hardest phase. The fracture surface evidenced a typical ductile failure. Furthermore, heat treatment results revealed that phase composition remained stable after annealing up to 650 °C. Phase transformation occurred at higher temperatures in order to form more stable phases; therefore, FCC2 phase grew at the expense of the BCC phase.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Microstructural and Mechanical Characterization of Directionally Solidified Conventional and Nb-Modified Mar-M247 Superalloy

This study analyzes the effects of replacing Ta by Nb (at.% basis) in the phase transformation temperatures, Scheil solidification behavior, and microstructural mechanical features of a Nb-modified as well as conventional Mar-M247 superalloys. Both alloys were directionally solidified at a withdrawal rate of 18 cm/h under a thermal gradient of about 80 °C/cm. DSC results were compared to thermodynamic simulations of phase transformation temperatures and showed a good correlation. The replacement of Ta by Nb has not altered the solidification path of Mar-M247, keeping the sequence L → L + γ → L + γ + MC → L + γ + MC + γ/γ′ eutectic. Due to the segregation of Hf and Zr to the very last liquid to solidify, a low melting point γ/Ni{sub 5}(Hf,Zr) constituent was observed. The as-solidified microstructures of both Mar-M247(Nb) and Mar-M247 were constituted of columnar dendrites of gamma matrix (γ) phase with cuboidal gamma-prime (γ′) precipitates. In addition, γ/γ′-eutectic was observed in the interdendritic region along with MC carbides in blocky, script (blocky dendritic), needle-like and fine nodular morphologies. Both alloys contained about 1.5 vol.% of MC carbides. The MC carbides in Mar-M247(Nb) and Mar-M247 are, respectively, Nb-rich and Ta-rich, with only a limited amount of Hf being detected in the MC phase. The yield stress of Nb-modified Mar-M247 showed higher values up to 750 °C. For higher temperatures, above 800 °C, a conventional Mar-M247 presented a higher value of yield stress.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Drawing Direction Effect on Microstructure and Mechanical Properties of Twinning-Induced Plasticity Steel During Wire Drawing

The effect of drawing direction on microstructure and mechanical properties in twinning-induced plasticity (TWIP) steel during wire drawing has been investigated to improve drawability for wire rod applications. The steel wires subjected to unidirectional (UD) and reverse-directional (RD) wire drawing were analyzed. The yield and tensile strength processed by the RD were slightly higher than those by the UD, whereas the ductility and drawability have inverse features, which is totally different from the results of plain carbon steel and Al wire. Although final shear strain of wires deformed by the RD is lower than that by the UD, the RD wires had a more complex stress history and a higher <111> texture component at the surface area, which encouraged twinning rate, resulting in fast exhaustion of ductility, finally earlier fracture of wires. In contrast to the materials deformed by mainly slip mechanism, the RD process cannot improve the ductility and drawability in TWIP steel due to the stress state dependency of twinning mechanism. Also, based on the different strengthening behaviors between pearlitic and TWIP steels during UD and RD, it is induced that microstructure and applied stress state simultaneously control the mechanical properties.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Ca and Sm Combined Addition on the Microstructure and Elevated-Temperature Mechanical Properties of Mg-6Al Alloys

In the present study, the microstructure and elevated-temperature mechanical properties of Mg-6Al, Mg-6Al-4Ca, Mg-6Al-4Sm and Mg-6Al-2Ca-2Sm alloys were investigated. The experimental results showed that the microstructure and elevated-temperature mechanical property of Mg-6Al alloy changed obviously with the different elements addition. By analyzing the results of optical microscope, x-ray diffraction analysis, scanning electron microscope, and transmission electron microscope, it could be determined that there was only Mg{sub 17}Al{sub 12} phase in Mg-6Al alloy, there were Al{sub 2}Ca and (Mg, Al){sub 2}Ca phases in Mg-6Al-4Ca alloy, there were Al{sub 2}Sm and Mg{sub 17}Al{sub 12} phases in Mg-6Al-4Sm alloy, and there were (Mg, Al){sub 2}Ca, Al{sub 2}Ca and Al{sub 2}Sm phases in Mg-6Al-2Ca-2Sm alloy. In addition, the addition of alloying elements including Ca and Sm, especially the composite addition, could significantly improve the tensile properties of Mg-6Al alloy. Compared to Mg-6Al alloy, the tensile strengths of Mg-6Al-2Ca-2Sm alloy at 448, 473 and 498 K were enhanced by 50.32, 87.92, and 94.99%, respectively. Furthermore, when the stretching temperatures were 448 and 473 K, the fracture pattern of Mg-6Al-2Ca-2Sm alloy was the mixture of intergranular fracture and trans-crystalline fracture. However, when the stretching temperature was 498 K, the fracture pattern of Mg-6Al-2Ca-2Sm alloy was the intergranular fracture.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Microstructure and Work Hardening Behavior of Micro-plasma Arc Welded AISI 316L Sheet Joint

The aim of this research is to investigate the microstructural changes and work hardening behavior of AISI 316L 0.5-mm-thick sheet due to micro-plasma arc welding. AISI 316L similar sheets were welded in single-pass square butt joint configuration. The microstructure in the fusion zone typically contains a variety of complex δ-ferrite-austenitic structure, which significantly increased hardness value compared to the base material because of rapid solidification of the weld pool. Systematic tensile test was performed to investigate strain rate sensitivity of the welded joint under quasi-static loading conditions. The multistage work hardening behavior was determined by Kocks–Mecking (K–M) model and differential Crussard–Jaoul analysis. In both the cases, stage III work hardening behavior and stage IV work hardening behavior were observed. The stress–strain curves of welded specimen at different strain rates were analyzed in terms of Hollomon, Ludwik and Swift equations to determine work hardening exponent values. The welded joints were ruptured in the transition zone of heat affected and fusion zones. The fractographic observation exhibited variation in dimple and void density over strain rate from 0.0001 to 0.0015 s{sup −1}.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Influence of Indium on Microstructure and Properties of Sn-Pb Binary Alloy Applied in Photovoltaic Ribbon

In this work, the conductivity, melting point, microstructure, spreading behavior, and mechanical properties of three types of Sn-Pb-In(indium) alloys are investigated along with Sn60Pb40 alloy as a reference. The results show that the In element improves the comprehensive properties of the Sn-Pb alloys. The maximum conductivity of the Sn-Pb-In alloys is 7.08 MS/m when the content of the In element is 3 wt.%. With an increasing content of the In element, the melting points of the Sn-Pb-In alloys gradually decrease from 183 to 166 °C. The microstructures of the alloys are refined with the addition of In. The intermetallic compound (IMC) InSn{sub 4} is only found in Sn60Pb34In6, except for the α-Pb and β-Sn phases. A spread test shows that only IMC Cu{sub 6}Sn{sub 5} is present at the Cu/solder interface of the solder joints. The Sn60Pb34In3 solder joint shows the highest ultimate tensile strength of 54 MPa. The microhardness of the alloys slightly increases from 12.76 HV{sub 0.05} to 13.56 HV{sub 0.05} with the In content increasing from 0 to 3 wt.%, while a sharp increase to 15.53 HV{sub 0.05} is observed when the amount of In exceeds 3 wt.%.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Fabrication, Microstructures, and Properties of 50 vol.% SiCp/6061Al Composites via Hot Pressing

Nearly fully dense 50 vol.% SiCp/6061Al composites were fabricated via hot pressing (HPing) at temperatures ranging from 610 to 650 °C, with the axial load and holding time fixed as 25 MPa and 120 min, respectively. The interfacial reactions, microstructures, and properties of the SiCp/Al alloy were studied. The interface reaction between SiCp and the Al alloy was suppressed at annealing temperatures of 620 °C and below; however, the reaction intensified as the annealing temperature increased, producing Al{sub 4}C{sub 3}, Si, and Mg{sub 2}Si. With an increase in HPing temperature from 610 to 630 °C, the 6061Al alloy melted and gradually filled the pores in the SiC particles under the applied load. The density, bending strength, and thermal conductivity (TC) of the composites increased, whereas the coefficient of thermal expansion (CTE) of the composites decreased. With an increase in HPing temperature increased from 630 to 650 °C, the 6061Al alloy melt leaked through the sintered bodies, resulting in the microstructural degradation and property reduction of the composites. The 50 vol.% SiCp/6061Al composites fabricated by HPing at 630 °C exhibited optimal comprehensive properties [bending strength, 332.4 MPa; TC, 186.3 W(m K){sup −1}; and CTE, 7.9 × 10{sup −6}/°C (20-100 °C)], which were attributed to the highest relative density and the best SiCp/Al interfacial structure of the composites.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Microstructural Stability During Creep Exposure of 9Cr-1Mo Steel Treated at Different Normalization Temperatures

A modified 9Cr-1Mo steel has been exposed to three separate austenitization temperatures, i.e., at 950, 1025, and 1100 °C for normalization. After subsequent tempering at 750 °C, the normalized and tempered samples were creep-tested at temperatures of 550, 600, and 650 °C. The creep strength of the investigated samples was evaluated in terms of minimum creep strain rate and time to rupture. The effects of microstructure, precipitate and boundary misorientation on the creep behavior of the samples have been studied with TEM and EBSD analyses. Further, the evolution of crystallographic texture after creep tests has also been studied. The presence of an intermediate size of martensitic microstructural units (i.e., prior-austenite grain, martensitic packets, etc.) and combination of fine coherent and incoherent Nb(C,N) precipitates has provided superior creep strength for the samples normalized at 1025 °C, when these are subsequently subjected to low-temperature (i.e., 550 °C) and high-temperature (i.e., 650 °C) creep tests, as compared to other conditions of normalizing heat treatment.

36 MATERIALS SCIENCE↗
DOE OSTI2019

A Comparative Study of Constitutive Characteristics and Microstructure Evolution between Uniaxial and Plane Strain Compression of an AA6061 Alloy

The hot deformation behavior of an AA6061 alloy was comparatively studied by uniaxial compression (UC) and plane strain compression (PSC) in the temperature range of 300-450 °C and strain rate range of 0.01-5 s{sup −1}. The processing maps were constructed based on a dynamic materials model, and the associated microstructures were observed. Under the same deformation conditions, the flow stress of the AA6061 alloy during PSC is higher than that during UC, which can be characterized by the Zener–Hollomon (Z) parameter in a hyperbolic sine-type equation with an activation energy Q of 175.2 kJ mol{sup −1} and 201.9 kJ mol{sup −1}, respectively. In addition, the instability domain is narrower under PSC compared to that under UC. The observed microstructures also indicate that as the Z value decreases, the tendency of dynamic recrystallization increases during PSC. The softening mechanisms in the AA6061 alloy after PSC and UC mainly consist of the dynamic recovery that is accompanied by a slight dynamic recrystallization. The optimum parameters are in the temperature range of 360-450 °C and strain rate range of 0.03-0.3 s{sup −1} for UC, and for PSC, the optimum parameters are in the temperature range of 320-400 °C and strain rate range of 0.01-0.05 s{sup −1}.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Microstructural Characteristics and Mechanical Properties in the Laser Beam Welded Joints of High-Strength Microalloyed Steel

The laser beam welded joints of the high-strength microalloyed steel consist of the base metal (BM), the partially transformed heat-affected zone I (PTHAZ-I), the partially transformed heat-affected zone II (PTHAZ-II), the fully transformed heat-affected zone (FTHAZ) and the fusion zone (FZ). The martensite/austenite (M/A) islands of the bainites in the PTHAZ-II are dense versus those in the PTHAZ-I, and the martensites exist in the FTHAZ and the FZ together with the bainites under the slow welding speed. The M/A islands of the bainites and/or the martensites in the PTHAZ become denser under the high welding speed, and the martensites in the FTHAZ and the FZ predominate. The low-angle boundary density and the high local misorientation proportion are used to identify the constituents roughly, consistent with the microstructural characteristics in the welded joints. The misorientation angle distributions are employed to evaluate the degree of the phase transformation, reflecting the change law of the degree of the phase transformation in the welded joints. The hardness and the tensile tests indicate that the HAZ and the FZ are stronger than the BM, dependent on the microstructures in the welded joints. The strengthening in the HAZ and the FZ is mainly attributed to the products of non-equilibrium phase transformation with the high dislocation density.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Relationship Between Microstructure and Marine Corrosion Resistance of Martensitic Stainless Steels: A Multiscale Approach

The electrochemical properties of martensitic stainless steels may depend on complex aspects of their microstructure. Three alloys were considered in this study: X30Cr13 (AISI 420), a martensitic stainless steel with a low content of alloying elements; X17CrNi16-2 (AISI 431), chosen for its strong resistance to corrosion; and X5CrNiCu15-5 (AISI 630), chosen for its good mechanical resistance. Voltammetry tests have shown the influence of carbon and chromium content on corrosion resistance. Resistance to pitting appears equivalent for the both. However, heterogeneous corrosion, in relation to δ-ferrite precipitation and chromium carbides at the lath boundaries, appears in the case of X17CrNi16-2. Conversely, non-preferential corrosion occurs in the case of the X5CrNiCu15-5, and a superior passive film stability during immersion in artificial seawater. This counterbalance negative effect of the microstructure. Thus, it achieves an equivalent “macroscopically” corrosion behavior between the two steels.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Cobalt Content on Thermal, Mechanical, and Microstructural Properties of Al{sub 0.4}FeCrNiCo{sub x} (x = 0, 0.25, 0.5, 1.0 mol) High-Entropy Alloys

Al{sub 0.4}FeCrNiCo{sub x} (x = 0, 0.25, 0.5, 1.0 mol) high-entropy alloys are developed by arc melting route to investigate the effect of cobalt content on thermal, mechanical, and microstructural properties. The phase, microstructure, and chemical composition are analyzed using x-ray diffraction, transmission electron microscope, and scanning electron microscope with attached energy-dispersive x-ray spectrometer. The obtained results have shown that the Al{sub 0.4}FeCrNiCo{sub x} (x = 0-0.5 mol) high-entropy alloys form a simple FCC + BCC-type solid solution and Al{sub 0.4}FeCrNiCo{sub x=1} HEA forms a single-phase FCC structure. The compressive yield strength, microhardness, and thermal conductivity are observed to decrease from 965.22 to 233.37 MPa, 253.6 to 155.6 HV, and from 4.87 to 2.674 W/mK, respectively, whereas the electrical resistivity is observed to increase from 150.30 to 273.74 µΩ-cm with the addition of cobalt from x = 0-1 mol. Differential scanning calorimetry analysis has indicated that the Al{sub 0.4}FeCrNiCo{sub x} (x = 0, 0.25, 0.5, 1.0 mol) high-entropy alloys are thermally stable up to 1000 °C.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Deformation Behavior and Microstructure Evolution of Powder Metallurgy Ti6Al4V Alloy During Hot Compression

In order to determine appropriate workability parameters for cross-wedge rolling products of powder metallurgy (PM) Ti6Al4V alloys, thermal compression experiments were carried out within the temperature range of 850-1050 °C, the strain rate range of 0.1-10 s{sup −1}, and with a height decrease of 60%. The compression deformation behavior was investigated. A strain-compensated constitutive model was established based on the flow stress curves corrected by the friction, which can predict the flow behaviors under the entirety of the experimental deformation conditions. Moreover, the processing map was developed, and stable and unstable deformation regimes were established. The microstructure analysis illustrated that globularization and dynamic recrystallization were the main deformation mechanisms. The porosity of the compressed samples was greatly reduced and influenced by the temperature and strain rate. Considering the material flow stress, hot processing map, microstructure and porosity, the appropriate hot deformation parameters for PM Ti6Al4V alloy preforms are suggested.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Anisotropy on Microstructures and Mechanical Properties of Rolled Ti/Al/Mg/Al/Ti Laminates

TA2/5052Al/AZ31/5052Al/TA2 five-ply laminates were fabricated by hot rolling, and the effect of anisotropy on their microstructures and mechanical properties was studied. After rolling, the Mg/Al and Al/Ti interfaces were both closely connected, but the interfacial shapes were totally different. For the Mg layer microstructures in the middle area, regardless of the direction, dynamic recrystallized (DRXed) grains appeared around the deformation bands. However, twins and a shear zone appeared in the RD sample; the twins decreased in the sample along the 45° angle, and no twins appeared in the TD sample. The Ti layer showed equiaxed grains in different directions, which were attributed to the ability of Ti alloy to anti-deform. The tensile testing results showed that the fracture of the Ti/Al/Mg/Al/Ti laminates can be divided into four stages. The laminate had an ultimate tensile strength of 434 MPa and excellent elongation along the rolling direction (RD), which were attributed to its DRXed grains and twins. In conclusion, the laminates had significant anisotropy due to the presence of Mg alloys.

36 MATERIALS SCIENCE↗