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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 919 records · Page 51
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Hot-worked microstructure and hot workability of cold-work tool steels

Highlights: • Hot compression tests were conducted for D2 and an 8% Cr steel. • Processing maps were constructed for the evaluation of their hot workability. • They had similar hot workability concerning the flow instability. • The 8% Cr steel exhibited a larger resistance to dynamic recrystallization. - Abstract: The hot workability of two cold-work tool steels were evaluated and compared. A D2 and an advanced alloy based on 8% Cr steels (TDx) were deformed at high temperatures between 900 and 1100 °C with strain rates 0.001–10 s{sup − 1} via hot compression test. From the flow curves, processing maps were constructed based on the dynamic material model. The deformed microstructures were observed and compared in various scales with respect to the deformation conditions. Although the two alloys exhibited a large similarity in the flow instability consideration of the processing map, their behavior in microstructure evolution was different. While both alloys exhibited a tendency of strain localization in the conditions of instability, the efficiency of power dissipation in the processing maps showed an intricate correlation with the progress of dynamic recrystallization and carbide precipitation. TDx showed a distinctive behavior of carbide precipitation and a larger resistance to dynamic recrystallization, which implied a requirement on more delicate control of hot working conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Adversarial Ensemble Modeling of Multi-modal Mechanical Properties for Iron-Based Alloys

Mechanical properties of alloys are controlled by their microstructure; and microstructure evolution is controlled by internal and external stressors. Chemical complexity during the alloy processing may result in heterogeneity and observation of multimodal performance patterns. Thus, to ensure the desired performance of stressed components it is important to understand the origin and mechanisms of such behavior. Adversarial ensemble modeling was introduced here to explain multimodal mechanical properties of the iron-based alloys. The modeling results showed that the areas of a single mechanism predominance were contiguous across the alloy compositions clustered by similarity, with sharp and persistent boundaries separating the single-mechanism domains. The marginal compositions resulted in increased competition between the adversarial models but only led to the multimodal behavior when the competing models diverged. Transparency of the clustering method allowed explicit interpretation of the chemistries leading to such competition. The adversarial ensemble was interpreted through transition from ductile to brittle microstructure.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Atomically Revealing Bulk Point Defect Dynamics in Hydrogen‐Driven γ‐Fe 2 O 3 → Fe 3 O 4 → FeO Transformation

Understanding how point defects in the bulk govern redox transformations is essential for advancing hydrogen-based metal production and designing high-performance oxide materials. This study reveals the atomic-scale mechanisms driving hydrogen-induced reduction of γ-Fe 2 O 3 to Fe 3 O 4 , focusing on how bulk vacancy dynamics dictate structural evolution and reaction kinetics. A key finding is the pronounced contrast in defect behavior between the two oxides: in γ-Fe 2 O 3 , intrinsic Fe vacancies promote oxygen vacancy clustering, destabilizing the local lattice and driving nanopore formation. In contrast, Fe 3 O 4 exhibits a higher oxygen vacancy formation energy and lacks intrinsic Fe vacancies, suppressing vacancy aggregation and maintaining a dense, pore-free structure. This divergence governs distinct reduction pathways—γ-Fe 2 O 3 undergoes an interface-reaction-limited transformation confined to the γ-Fe 2 O 3 /Fe 3 O 4 boundary, while Fe 3 O 4 supports a uniform increase in oxygen vacancy concentration, enabling bulk-phase reduction to lower-oxide FeO. Integrated in situ electron microscopy and density functional theory modeling uncover a vacancy-mediated mechanism, where synergistic cation-anion vacancy dynamics steer microstructure evolution and phase progression. These insights highlight the critical role of vacancy dynamics in controlling oxide reactivity and offer a pathway toward vacancy engineering to enhance reduction kinetics in hydrogen metallurgy and to tailor porosity, reactivity, and structural resilience in oxide-based catalysts and energy materials.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Dissimilar Joining of Pure Aluminum to SiC{sub p}/Al-MMCs Using an AlMgGaLi Active Interlayer Foil

To broaden the application of advanced metal matrix composites in the electronic packaging industry, a lead-free AlMgGaLi interlayer was developed for active soldering of aluminum to aluminum metal matrix composites. The effect of joining pressure on the microstructure evolution, interfacial wettability and mechanical properties of the dissimilar joints was investigated. The experimental results indicated that as the joining pressure increased, the mean thickness of the bond seam was 46.02 μm, and solidification of a solid solution occurred (detected by SEM/XRD analysis). The composition of the Al-based solid solution (in atom%) was 86.52% Al, 9.32% Mg, 2.56% O, 1.5% Ga and 0.1% Si. The pressure improved the interfacial wettability by enhancing the atom diffusion between the interlayer and parent materials. The joint shear strength initially increased and then decreased, and a sound joint with a maximum shear strength of ~ 45 MPa was produced at 450 °C and 0.75 MPa. The fracture crack initially occurred at the interfaces of the Al/filler metal and then propagated mainly along the Al{sub 2}O{sub 3} layer on the Al side. A novel model describing the pressure-induced microstructure changes within the joint and the formation of an Al{sub 2}O{sub 3} diffusion barrier layer at the Al/filler metal interface is proposed.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Formation of gradient microstructure and mechanical properties of hot-pressed W-20 wt% Cu composites after sliding friction severe deformation

Highlights: • W particles of composites were refined during sliding friction treatment (SFD). • Dislocation, dislocation tangles and boundary clearly exist in deformed W particle. • YS and UTS of SFDed sample are 308.74 MPa and 553.60 MPa owing to the refinement. • Electrical conductivity of SFDed sample decreased from 33 IACS% to 28.5 IACS%. • Fracture mode changing from inter-granular mode to trans-granular. - Abstract: W-based alloys are currently considered promising candidates for high heat flux components in future fusion reactors. In this paper, hot pressed W-20 wt%Cu composites were treated at room temperature using a sliding friction severe deformation (SFD) process, with a moving speed of 0.2 m/s and an applied load of 500 N. Microstructural evolution of composites after the SFD treatment was evaluated and compared with that of the untreated composites. Results showed that there was a gradient structure generated and an obvious refinement in tungsten particles size in the surface layer after the SFD process. The average particle size of tungsten in the SFD treated composites was 2.60 μm, whereas it was 4.5 μm for tungsten in the untreated composites. Fracture surfaces of the composites indicated that the SFD treatment destroyed the W skeleton and changed fracture mode from predominant inter-granular one to trans-granular one due to the decrease in contact area of W-W inter-particles. Yield strength and ultimate tensile strength of composites after the SFD treatment were 308 MPa and 553 MPa, respectively. The treated composites exhibited micro-hardness values with an average reading of about 308 HV. Analysis of the facture microstructures clearly suggested that the tungsten particles in the treated composites are consisted of dislocations and boundaries as well as dislocation tangles. The electrical conductivity of the composites was decreased from 33 IACS% to 28.5 IACS% after the SFD treatment, mainly due to loss or squeezing of copper into the inner surface.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Ion irradiation induced element-enriched and depleted nanostructures in Zr-Al-Cu-Ni metallic glass

The microstructural evolution of a Zr-Al-Cu-Ni metallic glass induced by irradiation with Ar ions was investigated. Under ion irradiation, the Cu- and Ni-enriched nanostructures (diameter of 30–50 nm) consisted of crystalline and amorphous structures were formed. Further, Cu- and Ni-depleted nanostructures with diameters of 5–20 nm were also observed. The formation of these nanostructures can be ascribed to the migration of Cu and Ni atoms in the irradiated metallic glass.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2021

Joining AA7099 to Ni-Cr-Mo Steel Using Single Pass Friction Stir Dovetailing and AA6061 Butter Layer

A novel single pass friction stir dovetailing (FSD) was developed to join thick plate AA7099 to Ni-Cr-Mo steel in a lap configuration through the use of an AA6061 butter layer. The butter layer approach can be shown to significantly reduce interfacial failures by inhibiting the formation of brittle Fe–Al intermetallic compounds (IMCs) which are typically formed during conventional friction stir welding (FSW) of AA7099 directly to steel. This study evaluates the strength and microstructural evolution of the aluminum/steel joint interface between single pass FSD of AA7099/AA6061(butter)/steel fabricated using three different FSD tool configurations. The butter layer was achieved by placement of a free-floating strip of AA6061 within the dovetail groove that was pre-machined in the steel substrate. Friction stir welding was then used to simultaneously join the thick plate AA7099, the AA6061 strip and the AA7099 in a single weld pass. To optimize the joining process, three different pin geometries (full thread, half smooth/half thread, no thread) were evaluated; it was demonstrated that the half smooth/half thread tool produced the strongest weld joint due to the absence of a Zn rich layer at the Al/steel interface. The efficacy of this unique processing technique was tested using lap shear tensile testing as well as high resolution transmission electron microscopy (TEM). A discussion of the new FSD technique, joint configurations, and process parameters are provided along with joint microstructural analyses and mechanical performance.

Olszta, Matthew J.↗
DOE OSTI2025

An atomistic study connecting underlying dislocation behavior with superior mechanical properties of NiCoCr medium entropy alloy

NiCoCr-based medium-entropy alloy (MEA) with a simple face-centered cubic crystal phase exhibits excellent mechanical properties, often attributed to the synergy of multiple deformation mechanisms. However, the atomistic origin of their outstanding mechanical response, including microstructural evolution and dislocation behavior under varying strain-rates and orientation, remains unclear. In this work, we employ large-scale molecular dynamics (MD) simulations to investigate the changes in deformation mechanisms along three distinct orientations ([110], [111], [100]) under varying strain rates (1 ×10 8 /sec, 1 ×10 10 /sec, 1 ×10 12 /sec) in the NiCoCr MEA. The presence of the stair-rod and the Shockley partial dislocations under uniaxial tensile strain are found to play a key role in the formation of deformation twinning and ε-martensite, which positively correlates with strain-rate dependent dislocation analysis. These findings further establish the role of the dislocations in controlling the superior mechanical response and excellent fracture toughness of the NiCoCr MEA. Systematic transmission-electron microscopy tests performed on the [111]-oriented crystals, deformed at different strain levels, at room temperature provide clear evidence of both the extended stacking-fault and the stair rods, confirming the predicted microstructural features. Finally, this study offers key insights into the complex nucleation mechanisms of deformation twinning and ε-martensite, such as twinning – and transformation–induced plasticity (TWIP-TRIP), providing valuable guidelines for studying similar material classes.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Experimental investigation of the dependence of void nucleation and growth on initial microstructure in high-purity titanium under tension

An experimental investigation of failure mechanisms in relation to the initial microstructure in high-purity titanium samples is presented. The initial microstructure of the specimens was measured in 3D using diffraction-contrast tomography (DCT). Ex-situ X-ray computed tomography (XCT) was used to visualize voids in specimens at various levels of deformation attained by interrupted tensile testing. Electron backscatter diffraction (EBSD) mapping was used to characterize the deformed microstructures per specimen. The investigation showed that the location of failures was unrelated to the formation of the first voids, but rather the nucleation and growth of cracks were from heavily deformed surface regions. The areas surrounding the failure-causing cracks had the highest propensity for void development of any area in the specimen. This facilitated crack propagation through the specimen via “linking up”. The failure of the specimens by microvoid coalescence was bolstered by “dimpled” fracture surfaces. Paint composed of gallium embedded in rubber was used to track the displacement of points along the loading direction of the specimens, to relate the location of failure to the material's initial microstructure. However, the correlation proved difficult, due to complex microstructural evolution involving voids, grain fragmentations, and profuse twinning. Nevertheless, it was shown that necking occurred near the largest grain in the gauge section of the specimens. This is likely caused by the decrease in strength of larger grains, causing strain to concentrate in their vicinity. Here, a comprehensive picture of the failure processes in high-purity titanium under axial loading is presented and discussed in the paper.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Influence of severe plastic deformation on intermetallic particles in Mg-12 wt.%Zn alloy investigated using transmission electron microscopy

The in-depth microstructural characterization of intermetallic particles in an Mg-12 wt.%Zn binary alloy subjected to a severe plastic deformation is presented. The alloy was processed by four passes via equal channel angular pressing with an applied back pressure at a gradually decreasing temperature and analyzed using transmission electron microscopy techniques to observe the influence of processing on intermetallic particles. The results are compared with the initial state of the material prior to severe plastic deformation. The microstructural evolution of the α-Mg matrix and the Mg{sub 21}Zn{sub 25}, Mg{sub 51}Zn{sub 20} and MgZn{sub 2} was analyzed using bright field imaging, selected area electron diffraction, high-resolution transmission electron microscopy and high-angle annular dark field imaging in scanning mode. The plastic deformation process influenced the α-Mg matrix and each type of intermetallic particle. The α-Mg matrix consisted of two types of areas. The first type of area had a highly deformed structure, and the second type of area had a partially recrystallized structure with an average grain size of approximately 250 nm. The Mg{sub 21}Zn{sub 25} microparticles exhibited distinct forms in the α-Mg matrix that were characterized as a single-crystalline form, a nano-crystalline form and a broken up form. No evidence of Mg{sub 51}Zn{sub 20} nanoparticles within the α-Mg matrix was found in the microstructure, which indicates their dissolution or phase transformation during the deformation process. MgZn{sub 2} nanoparticles exhibited different behavior in both types of α-Mg matrix. Two orientation relationships toward the highly deformed α-Mg matrix were observed; however, there was no relationship toward the partially recrystallized α-Mg matrix. Additionally, the growth of the MgZn{sub 2} nanoparticles was different in the two types of α-Mg matrix. The Mg{sub 51}Zn{sub 20} nanoparticles inside Mg{sub 21}Zn{sub 25} microparticles exhibited a distinct behavior within the single-crystalline or nano-crystalline form of the parent Mg{sub 21}Zn{sub 25} microparticles. The Mg{sub 21}Zn{sub 25} + Mg{sub 51}Zn{sub 20} eutectic compound was confirmed for both forms of the parent Mg{sub 21}Zn{sub 25} microparticles, and the growth of Mg{sub 51}Zn{sub 20} nanoparticles is discussed. - Highlights: •Comprehensive microstructure characterization of Mg-12 wt.%Zn alloy after ECAP-BP •TEM analysis of changes of intermetallic phases caused by SPD •Mg{sub 21}Zn{sub 25} particles exhibit nano-crystalline regions with grain size below 100 nm. •MgZn{sub 2} preserved its orientation relationship toward highly deformed α-Mg after SPD. •Existence of Mg{sub 21}Zn{sub 25} + Mg{sub 51}Zn{sub 20} eutectic remained for each Mg{sub 21}Zn{sub 25} particle form.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Ostwald ripening of faceted Si particles in an Al-Si-Cu melt

The microstructural evolution of an Al-Si-Cu alloy during Ostwald ripening is imaged via synchrotron-based, four-dimensional (i.e., space and time resolved) X-ray tomography. Samples of composition Al-32 wt%Si-15 wt%Cu were annealed isothermally at 650 °C, in the two-phase solid-liquid regime, while tomographic projections were collected in situ over the course of five hours. Advances in experimental methods and computational approaches enable us to characterize the local interfacial curvatures and velocities during ripening. The sequence of three-dimensional reconstructions and interfacial shape distributions shows highly faceted Si particles in a copper-enriched liquid, that become increasingly isotropic or rounded over time. In addition, we find that the coarsening rate constant is approximately the same in the binary and ternary systems. By coupling these experimental measurements with CALPHAD modeling and ab initio molecular dynamics simulation, we assess the influence of Cu on the coarsening process. Lastly, we find the unusual “pinning” of microstructure at the junction between rough and smooth interfaces and suggest a mechanism for this behavior.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Prediction and characterization of heat-affected zone formation in tin-bismuth alloys due to nickel-aluminum multilayer foil reaction

Reactive multilayer foils have the potential to be used as local high intensity heat sources for a variety of applications. In this study, most of the past research effort concerning these materials have focused on understanding the structure-property relationships of the foils that govern the energy released during a reaction. To improve the ability of researchers to more rapidly develop technologies based on reactive multilayer foils, a deeper and more predictive understanding of the relationship between the heat released from the foil and microstructural evolution in the neighboring materials is needed. This work describes the development of a numerical model for the purpose of predicting heat affected zone size in substrate materials. The model is experimentally validated using a commercially available Ni-Al multilayer foils and alloys from the Sn-Bi binary system. To accomplish this, phenomenological models for predicting the variation of physical properties (i.e., thermal conductivity, density, and heat capacity) with temperature and composition in the Sn-Bi system were utilized using literature data.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Microstructures and Impact Wear Behavior of Al-Alloyed High-Mn Austenitic Cast Steel After Aging Treatment

The microstructural evolution and impact wear behavior of Al-alloyed ultra-high-Mn austenitic cast steel were investigated after different heat treatments, including quenching (Q) and quenching + aging (Q + A). Another ultra-high-Mn austenitic cast steel without Al was compared under the same experimental condition. After Q + A, Al addition contributed to the precipitation of κ-carbides which improves the yield strength and wear resistance of the austenite matrix. However, the mechanical properties and wear resistance of the Al-free steel were strongly deteriorated due to the precipitation of plate-like M{sub 3}C-type carbides, as well as the worn surface of the Al-free steel had the feature of micro-scratches. After Q + A (2 h), the Al-alloyed steel obtained optimal wear resistance and the main wear feature was strain fatigue. But, excessive aging time (4 h) would lead to a large fragile peeling from the worn surface and the wear resistance was decreased. Also, the worn subsurface microstructures with different heat treatments were observed by transmission electron microscopy (TEM). These results show that the deformation microstructures of the Al-free steel contained stacking faults, dislocation tangle and deformation twins. The deformation character of Al-alloyed steel is dominated by planar glide, and with increase in the aging time, planar dislocation substructures gradually evolved, relating to dislocation pileups, Taylor lattices and micro-bands.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Effect of Ni content on the microstructure and mechanical properties of weld metal with both-side submerged arc welding technique

Highlights: • This manuscript primarily studied the effects of Ni content on the K65 weld metals; • Increase Ni content could significantly improve the strength and low temperature impact toughness of the weld metal. • The beneficial effect of Ni is attributed to its positive effect on phase transformation. • GBF keeps K-S or N-W relations only with one austenite and the variants belong to the same bain group are two reasons. • The M/A islands are considered to be another reason for the reduced toughness. - Abstract: The effects of nickel (Ni) content on the mechanical properties and microstructure evolution in the weld metals of commercial K65 oil and gas pipeline steel were studied. Increase Ni content could significantly improve the strength and low temperature impact toughness (−40 °C and −60 °C) of the weld metal. The above influences of Ni were attributed to the formation of predominant acicular ferrite (AF), at the expense of grain boundary ferrite (GBF), ferrite side plates (FSP) and martensite/austenite (M/A) constituent in weld metal. EBSD results indicated that GBF keeps K-S or N-W relations only with the prior austensite grain that belongs to one side of the grain boundary and the variants belong to the same bain group which always forms low angle boundary. Moreover, the retained austenite as one part of M/A constituent was mainly found in the weld metal with lower Ni content. It indicated that the transformation process could be promoted more completely by the increase of Ni content. The mechanism of the toughness improvement brought by Ni increasing was ascribed to the relatively uniform transformation to final microstructure, which reduces the appearance of GBF and M/A constituents.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Effects of Sodium Exposure on the Tensile Properties of Grade 91 steel

Two heats of G91 steel have been investigated in liquid sodium at 550- 650°C to understand their corrosion behaviour, microstructural evolution, and tensile properties. Sodium exposure experiments of subsized, sheet-type tensile specimens of G91 were performed in Argonne’s forced convection sodium materials testing loops, SMT-1 and SMT-2. Maximum exposure times of ~49,000 h at ~38,000 h, and ~20,000 h have been achieved at 550, 600, and 650°C, respectively. Thermal aging experiments of G91 steel were also conducted in parallel, and the results were compared with those of the sodium-exposed specimens to isolate the effect of thermal aging from the effect of sodium exposure. It was found that the yield stress and ultimate tensile strength of G91 were reduced by more than 50% after sodium exposures at 650°C due to decarburization. The reduction in tensile strength was accompanied by the dissolution of M 23 C 6 carbides and excessive grain growth. The effect of sodium at 550 and 600°C was insignificant for exposure times up to ~49,000 h and ~38,000 h, respectively. The effect of sodium on the microstructural stability and tensile properties of G91 is largely dependent on the carbon mass transfer in the alloy-sodium system.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2019

Effect of Heat Input on Microstructure, Residual Stress, and Corrosion Resistance of UNS 32101 Lean Duplex Stainless Steel Weld Joints

In the present work, the influence of heat input on phase balance, residual stresses and corrosion resistance of UNS 32101 lean duplex stainless steel welds has been investigated. Three weldment types were obtained with different heat inputs by varying welding current, using gas tungsten arc welding process. The results revealed that increasing heat input caused a significant microstructural evolution with high austenite fraction in weld metals. The residual stresses were measured on the surface and through the sample’s thickness by x-ray diffraction technique based on Sin{sup 2}ψ method. The results showed an inversely proportional relationship between the heat input and the compressive residual stresses on the surface and through the thickness of the weld metal. Potentiodynamic polarization tests of the different welded joints evaluated in 3.5% NaCl solution exhibited high corrosion resistance of the weld metal produced with the low heat input.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Experimental Study on Microstructure and Hardness of Pure Titanium Subjected to Torsion Deformation at Different Temperatures

The studies of mechanical property, microstructure evolution and fracture analysis in pure titanium processed by torsion deformation at 298, 673 and 1073 K are conducted systematically. The variations of mechanical property of deformed pure titanium are shown through Vickers hardness evaluation. During torsion at 298 K, the grains are refined and elongated, but the α phase with different shapes precipitates for twisted samples at 673 and 1073 K. The fracture appearance indicates that the elongated dimples occur on fracture surface at 298 K. Besides, a large number of shear facets are arranged. However, typical intergranular fracture appearance with lots of blocks in polyhedral shape covers the fracture surface at 673 and 1073 K, respectively.

36 MATERIALS SCIENCE↗