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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 955 records · Page 53
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Influence of Thermal Treatment on the Microstructure, Mechanical Properties, and Corrosion Resistance of Newly Developed Ti20Nb13Zr Biomedical Alloy in a Simulated Body Environment

The effect of thermal treatments on the microstructure, hardness, and electrochemical performance in a simulated body fluid were studied for the newly developed (β + α) Ti20Nb13Zr alloy (TNZ) for biomedical applications. The alloy was heat-treated for 1 h at 900 °C and then cooled at different cooling rates. Then, the solution-treated samples were aged at 400, 500, or 600 °C for 5 h. The phase evolution and microstructure of the treated alloy were examined using XRD and SEM/EDX analysis. The mechanical properties were assessed using microindentation. The surface protection performance against corrosion was assessed by potentiodynamic polarization and electrochemical impedance spectroscopic analysis. The obtained results showed that the wide range of microstructure with varied volume fraction and morphology of β and α were obtained with different heat treatment conditions. The different phases’ sizes and distributions influenced the microstructure obtained during the heat treatment, thereby affecting the mechanical properties. The corrosion performance significantly altered with variations in the microstructure of the TNZ alloy as a result of the different thermal treatments. The heat treatment of TNZ conferred enhanced combination of mechanical and corrosion protection compared to that of the commercial Ti6Al4V alloy.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Microstructure Reconstruction of Sheet Molding Composite Using a Random Chips Packing Algorithm

Fiber-reinforced polymer composites are strong candidates for structural materials to replace steel and light alloys in lightweight vehicle design because of their low density and relatively high strength. In the integrated computational materials engineering (ICME) development of carbon fiber composites, microstructure reconstruction algorithms are needed to generate material microstructure representative volume element (RVE) based on the material processing information. The microstructure RVE reconstruction enables the material property prediction by finite element analysis (FEA)This paper presents an algorithm to reconstruct the microstructure of a chopped carbon fiber/epoxy laminate material system produced by compression molding, normally known as sheet molding compounds (SMC). The algorithm takes the result from material’s manufacturing process as inputs, such as the orientation tensor of fibers, the chopped fiber sheet geometry, and the fiber volume fraction. The chopped fiber sheets are treated as deformable rectangle chips and a random packing algorithm is developed to pack these chips into a square plate. The RVE is built in a layer-by-layer fashion until the desired number of lamina is reached, then a fine tuning process is applied to finalize the reconstruction. Compared to the previous methods, this new approach has the ability to model bended fibers by allowing limited amount of overlaps of rectangle chips. Furthermore, the method does not need SMC microstructure images, for which the image-based characterization techniques have not been mature enough, as inputs. Case studies are performed and the results show that the statistics of the reconstructed microstructures generated by the algorithm matches well with the target input parameters from processing.

Huang, Tianyu↗
DOE OSTI2019

The effects of material anisotropy on secondary processing of additively manufactured CoCrMo

Components produced by near net shape additive manufacturing processes often require subsequent subtractive finishing operations to satisfy requisite surface finish and geometric tolerances. It is well established that the microstructure and properties of the as-built component are sensitive to the additive processing history. Therefore, downstream secondary processes may be affected by the as-built components’ mechanical behavior. In this work we study the sensitivity of secondary machining operations on CoCrMo samples produced via laser powder bed fusion. Utilizing novel high-throughput mechanical testing, microstructure characterization, and a rigorous statistical analysis we investigate the degree of material anisotropy present in the as-built material. We then study the effects of this anisotropy on secondary processing via slot milling experiments. Our results indicate that mechanical anisotropy is driven by both the morphology of the microstructure as well as crystallographic texture. Furthermore, the machining force response is correspondingly sensitive to these sources of anisotropy, which has the potential to impact how manufacturers finish additively built parts.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Post irradiation examination of a uranium-zirconium hydride TRIGA fuel element

Low-enriched (LEU) U-ZrH fuel, with a 235 U content less than 20% of the total uranium, is being evaluated for possible use in different types of reactors, including space nuclear systems, light water reactors (LWRs) and micro-reactors. As a result, it is beneficial to better understand the macrostructural and microstructural changes that occur in this fuel during irradiation. This paper reports the results of the post irradiation examination of an LEU U-ZrH fuel element (30 wt.% U, <20% 235 U) using neutron radiography, precision gamma scanning, chemical analysis, optical metallography and scanning electron microscopy combined with energy dispersive spectroscopy and wavelength dispersive spectroscopy, where the fuel element was irradiated in a Training, Research, Isotope, General Atomics (TRIGA) reactor. Results of microstructural characterization indicated some dehydriding and cracking of the U-ZrH fuel occurred during irradiation; an axial and radial burnup gradient existed in the fuel during irradiation, as measured by gamma scanning and chemical analysis; negligible microstructural changes transpired during irradiation, based on comparison of irradiated and as-fabricated U-ZrH fuel microstructures; and, negligible, fission product-rich, phases could be resolved in a U-ZrH fuel that was irradiated to a calculated 20% depletion of 235 U.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2013

Relationship between dislocations and residual stresses in cold-drawn pearlitic steel analyzed by energy-dispersive X-ray diffraction

We analyzed the dislocation distribution of cold-drawn pearlitic-steel wire by using the line-profile analysis based on the energy dispersive X-ray diffraction (EDXD). Although this line-profile analysis requires a high resolution in reciprocal space, the resolution for EDXD is generally poor due to the energy resolution of the detector. Our analysis demonstrated that the resolution in the reciprocal space can be maximized at small scattering angles. Using the line-profile analysis based on the EDXD, the microstructural parameters such as the crystallite size and the dislocation density of the ferrite phase in the pearlitic steel were successfully analyzed. In addition, the distribution of the residual stress of the ferrite phase of a pearlitic steel wire was also analyzed using the EDXD measurement. - Highlights: • Energy dispersive X-ray diffraction is applied to the line-profile analysis. • Distribution of dislocations in ferrite in the pearlitic steel wire is analyzed. • Relationship between dislocations and residual stress is discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Advances and Achievements in In Situ Analysis of Corrosion and Structure–Property Relationship in Mg Alloys

Every year, TMS Magnesium Committee carefully selects a special topic in magnesium (Mg) related research and development not only having the hottest subject from both academic and industrial perspectives but also demonstrating major achievements within this subject. Following last year’s topic on Mg microallying [1], this year’s focus is on in-situ methods and associated techniques in their broad definition spanning from laboratory- to large- scale facilities to process monitoring. The applications of in-situ techniques have a wide spectrum from the analysis of melts and liquid-solid transitions to solid-state phenomena during thermo-mechanical processing and heat treatments to surface interactions with various environments. Therefore, such works are of significant interest to scientists working in the area of Mg alloy development as well as to a much broader audience from both academia and industry. This interest is primarily caused by challenges in the analysis of structure-property relationship in Mg alloys, and even cursory glance of literature reveals sharp increase of publications relevant to this topic recently. For instance, very high reactivity of Mg as well as its well-known propensity to substantially alter structure upon unloading in mechanical testing makes it difficult to understand and thus to simulate correlation between microstructures observed in post-mortem analysis and physical processes during testing or fabrication. However, recent advances in in-situ analysis based on large-scale research facilities such as neutron scattering and synchrotron radiation sources as well as microscopy-based, acoustic emission, and other more traditional techniques allowed significant achievements. Apart from apparent development of relevant experimental techniques, a significant part of this success should also be attributed to increasing accessibility of the facilities and simplification of their use from a user perspective. The selection of articles in this special topic is quite far from comprehensive review covering all aspects of in-situ methods available for metallic materials development. However, this was not the purpose in any case. Instead, this selection is intended to present several studies on Mg alloys and Mg-based composites with the use of in-situ techniques. In addition, it overviews two techniques, ‘Acoustic Emission’ (AE) and ‘Ambient-Pressure X-ray Photoelectron Spectroscopy’ (AP-XPS), that are rather novel to the Mg community. These studies are supposed to give readers representative examples of such techniques potential and to help in navigating the spectrum of modern state-of-the-art analytical methods facilitating the development of Mg alloys. These articles are organized in the order corresponding to typical Mg alloy lifecycle from material preparation and solidification to thermo-mechanical processing and product fabrication to degradation.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Electrochemically deposited BiTe-based nanowires for thermoelectric applications

Nanostructured materials systems such as thin-films and nanowires (NWs) are promising for thermoelectric power generation and refrigeration compared to traditional counterparts in bulk, due to their enhanced thermoelectric figures-of-merit. BiTe and its derivative compounds, in particular, are well-known for their near-room temperature thermoelectric performance. In this work, both the binary and ternary BiTe-based nanowires namely, BiTe and BiSbTe, were synthesized using template-assisted electrodeposition. Diameters of the nanowires were controlled by the pore sizes of the anodised alumina (AAO) templates used. Systematic study on the compositional change as a function of applied potential was carried out via Linear Sweep Voltanmetry (LSV). Chemical compositions of the nanowires were studied using Energy Dispersive X-ray Spectrometry (EDXS) and their microstructures evaluated using diffraction and imaging techniques. Results from chemical analysis on the nanowires indicated that while the Sb content in BiSbTe nanowires increased with more negative deposition potentials, the formation of Te{sup 0} and Bi{sub 2}Te{sub 3} were favorable at more positive potentials.

36 MATERIALS SCIENCE↗
NASA NTRS1997

SiC (SCS-6) Fiber Reinforced-Reaction Formed SiC Matrix Composites: Microstructure and Interfacial Properties

Microstructural and interfacial characterization of unidirectional SiC (SCS-6) fiber reinforced-reaction formed SiC (RFSC) composites has been carried out. Silicon-1.7 at.% molybdenum alloy was used as the melt infiltrant, instead of pure silicon, to reduce the activity of silicon in the melt as well as to reduce the amount of free silicon in the matrix. Electron microprobe analysis was used to evaluate the microstructure and phase distribution in these composites. The matrix is SiC with a bi-modal grain-size distribution and small amounts of MoSi2, silicon, and carbon. Fiber push-outs tests on these composites showed that a desirably low interfacial shear strength was achieved. The average debond shear stress at room temperature varied with specimen thickness from 29 to 64 MPa, with higher values observed for thinner specimens. Initial frictional sliding stresses showed little thickness dependence with values generally close to 30 MPa. Push-out test results showed very little change when the test temperature was increased to 800 C from room temperature, indicating an absence of significant residual stresses in the composite.

Singh, M.↗
DOE OSTI2021

Thermal stability of additively manufactured austenitic 304L ODS alloy

Thermal stability and high-temperature mechanical properties of a 304L austenitic oxide dispersion strengthened (ODS) alloy manufactured via laser powder bed fusion (LPBF) are examined in this work. Additively manufactured 304L ODS alloy samples were aged at temperatures of 1000, 1100, and 1200 °C for 100 h in an argon atmosphere. Microstructure characterization of LPBF 304L ODS alloy before and after the thermal stability experiments revealed that despite the annihilation of dislocations, induced cellular substructure by the LPBF process was partially retained in the ODS alloy even after aging at 1200 °C. The size of Y-Si-O nanoparticles after aging at 1200 °C increased from 25 to 50 nm. EBSD analysis revealed that nanoparticles retained the microstructure of LPBF 304L ODS and hindered recrystallization and further grain growth. At 600 °C and 800 °C, the yield stress of the 290 and 145 MPa were measured, respectively, which are substantially higher than 113 MPa, and 68 MPa for 304L at the same temperatures. Furthermore, the creep properties of LPBF 304L ODS alloy were evaluated at a temperature of 700 °C under three applied stresses of 70, 85, and 100 MPa yielding a stress exponent (n) of ~7.7; the minimum creep rate at 100 MPa was found to be about two orders of magnitude lower than found in the literature for wrought 304L stainless steel.

36 MATERIALS SCIENCE↗
NASA NTRSDate not supplied

Simultaneous Development and Robust Optimization of a Microstructure Dependent Material

Recent microstructure characterization techniques combined with Symbolic Regression(SR)analysis has been proven to generate white box plasticity models well suited for incorporation into FEA software.The current work builds upon those efforts and demonstrates the applicability of Sequential Monte-Carlo (SMC) methods within SR analysis to condense model development and robust optimization into a single, co-dependent process. In this project, SMC methods provide a mechanism through which the observed microstructure features and associated variability can be incorporated into the discovery phase of model development and simultaneously recover approximate parameter distributions through SR analysis. The demonstration utilized a data set consisting of tensile test results from a limited number of sample specimens with corresponding EBSD data from which microstructure features were characterized.The maximum threshold stress model in the Visco-Plastic Self-Consistent (VPSC) code developed by Los Alamos National Laboratories was calibrated using mechanical test data.Synthetic volume elements with statistically equivalent microstructure were generated with DREAM3Dbased on the observed EBSD data. VPSC was used to simulate the corresponding tensile test response for each of the synthetic volume elements. The simulated microstructure and tensile test data was used astraining datafor SMC-SR algorithm and the resulting model was validated with data from the original empirical data set.

Karl Garbrecht↗
DOE OSTI2015

High-strength bioresorbable Fe–Ag nanocomposite scaffolds: Processing and properties

High strength ductile iron-silver nanocomposite scaffolds were fabricated employing high energy attrition milling of micron-submicron powders, followed by cold sintering/high pressure consolidation. Particulate leaching method with soluble Na{sub 2}SO{sub 4} and K{sub 2}CO{sub 3} salts as porogens was used to create scaffolds with 50, 55, 60 and 73% volume fraction of pores. Part of specimens was annealed at 600, 800 and 900°C. Specimens were characterized employing X-ray diffraction, scanning electron microscopy (SEM) with electron probe microanalysis (EDS) and high resolution SEM. Mechanical properties were measured in compression and permeability was measured in permeameter based on Darcy’s law. Scaffolds with 50% and 55% porosity exhibited high compressive strength (18–22 MPa), compressive strength of 8–12 MPa was observed for scaffolds with 73% porosity. Treatments at 800 and 900°C result in increase of strength and ductility with some coarsening of microstructure. Best combination of compressive strength (15 MPa) and permeability (0.6{sup −6} cm{sup 2}) is close to the range of trabecular bone.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Effect of as-cast microstructure heterogeneity on aging behavior of a high-pressure die-cast A380 alloy

Highlights: • The surface layer hardened much faster than the central region during age. • More quantity of finer precipitates was found in the surface layer during age. • The surface layer had a lower activation energy of precipitation. • Si promoted the precipitation via inducing dislocations in matrix. - Abstract: Microstructure and hardness evolution of a vacuum-assistant die-cast A380 alloy during heat treatment were investigated. Both surface layer and central region of the casting component were analyzed in die-cast state, solutionized state and artificial age state. During the artificial age, the surface layer hardened more significantly than the central region due to faster precipitation and more refined hardening phases in the surface layer. Detailed analysis on the macro-segregation, microstructure morphology and grain size revealed that the different aging behaviors exhibiting in the surface and the central region were mainly attributed to a combining effect of the enrichment of Si and Cu at the surface layer, the fully-divorced morphology of eutectic in die-cast microstructure, and the presence of the externally solidified crystals at the central region. The presence of the Si particles, which exhibited quite different thermal expansion properties, changed the density and the distribution of the dislocations in the α-Al matrix, and consequently changed the precipitation of the hardening phases.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Influence of Two Different Salt Mixture Combinations of Na{sub 2}SO{sub 4}-NaCl-NaVO{sub 3} on Hot Corrosion Behavior of Ni-Base Superalloy Nimonic263 at 800 °C

Isothermal hot corrosion behavior of Nimonic263 alloy was studied under the influence of two different salt mixtures of 87.5 wt.% Na{sub 2}SO{sub 4} + 5 wt.% NaCl + 7.5 wt.% NaVO{sub 3} (3SM) and 74 wt.% Na{sub 2}SO{sub 4} + 21.7 wt.% NaCl + 4.3 wt.% NaVO{sub 3} (3SM-A) and also without salt mixtures up to 500 h at 800 °C. Corrosion kinetics showed that 3SM-A is more aggressive than 3SM. Multiple oxides, spinels, sulfides, vanadate compounds, and volatile compounds were observed during various hot corrosion reactions. The volatile compounds NaClO{sub 3} and CrMoO{sub 3}, and SO{sub 3} gas are attributed to the weight loss under both 3SMs. The Na{sub 2}SO{sub 4} of 3SM prevailed till 400 h, but that of 3SM-A disappeared within 5 h, as established conclusively by Raman spectra analysis. The sulfides plus internal oxide zone increased with the increased exposure duration as evident from the extensive EPMA analysis. Based on the critical analysis of corrosion kinetics and detailed microstructural characterization, fluxing and sulfidation followed by oxidation are identified as plausible hot corrosion mechanisms under both 3SMs. Besides, chlorination and high-temperature oxidation mechanisms occur under 3SM-A condition.

36 MATERIALS SCIENCE↗
NASA NTRS1991

Property and microstructural nonuniformity in the yttrium-barium-copper-oxide superconductor determined from electrical, magnetic, and ultrasonic measurements

The purpose of this dissertation was the following: (1) to characterize the effect of pore fraction on a comprehensive set of electrical and magnetic properties for the yttrium-barium-copper-oxide (YBCO) high temperature ceramic superconductor; and (2) to determine the viability of using a room-temperature, nondestructive characterization method to aid in the prediction of superconducting (cryogenic) properties. The latter involved correlating ultrasonic velocity measurements at room temperature with property-affecting pore fraction and oxygen content variations. The use of ultrasonic velocity for estimating pore fraction in YBCO is presented, and other polycrystalline materials are reviewed, modeled, and statistically analyzed. This provides the basis for using ultrasonic velocity to interrogate microstructure. The effect of pore fraction (0.10-0.25) on superconductor properties of YBCO samples was characterized. Spatial (within-sample) variations in microstructure and superconductor properties were investigated, and the effect of oxygen content on elastic behavior was examined. Experimental methods used included a.c. susceptibility, electrical, and ultrasonic velocity measurements. Superconductor properties measured included transition temperature, magnetic transition width, transport and magnetic critical current density, magnetic shielding, a.c. loss, and sharpness of the voltage-current characteristics. An ultrasonic velocity image constructed from measurements at 1mm increments across a YBCO sample revealed microstructural variations that correlated with variations in magnetic shielding and a.c. loss behavior. Destructive examination using quantitative image analysis revealed pore fraction to be the varying microstructural feature.

Roth, Don J.↗
DOE OSTI2017

Surface Layers of Zr-18%Nb Alloy Modified by Ultrasonic Impact Treatment: Microstructure, Hardness and Corrosion

Near-surface layers in Zr-18%Nb alloy were modified using ultrasonic impact treatment (UIT). The effects of the UIT processing time on a microstructural formation, omega/alpha precipitations, microhardness and corrosion are analyzed. XRD analysis, TEM and SEM observations and EDX characterization allow establishing the links between the microstructure, microhardness and corrosion behavior of the surface layers formed. At the strain extent up to e ≈ 0.3, structural formation occurs under influence of deformation induced heating, which facilitates omega precipitation in beta phase and mechanically induced oxygen transport and oxide formation. XRD analysis reveals moderate compressive residual stresses (− 160 MPa) and pronounced {110} texture after the UIT process. Generation of dislocations and hindering of their movement by nanoscale omega precipitates manifest themselves as the broadening of diffraction peaks occurred mainly owing to the lattice microstrains, and they provide marked strain hardening. The enhanced anticorrosion properties of Zr-18%Nb alloy in saline solution were concluded to be a result of the formation of a protective oxide film, {110} texture and compressive stresses.

36 MATERIALS SCIENCE↗
DOE OSTI2017

The influence of substrate moisture preparation on bond strength of concrete overlays and the microstructure of the OTZ

The influence of substrate moisture preparation on the direct shear bond strength of composite substrate-overlay specimens was evaluated. The substrate surface was exposed to four different moisture conditions prior to overlay application. A quantitative analysis of backscattered electron images of the microstructure of the overlay transition zone was carried out to quantify its properties along the interface and help analyse the results of the shear bond testing. The results show that pre-wetting the substrate surface prior to application of the overlay provides no added benefit towards increasing the bond strength and may in some cases reduce bond strength significantly. The microstructural investigations confirmed that pre-saturated substrates increase the w/c ratio and the porosity in the overlay transition zone (OTZ), which was found to have a thickness of about 100 μm. The OTZ in overlays cast on dry substrate surfaces had lower porosity and an increased amount of anhydrous cement.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Three-dimensional (3D) analysis of white etching bands (WEBs) in AISI M50 bearing steel using automated serial sectioning

Dark etching regions (DER) and white etching bands (WEB) form in the subsurface stressed regions of bearing raceways and rolling elements. Also, “butterfly” formations form around non-metallic inclusions and large carbides. The formation of WEBs, DERs and butterfly are dependent on operating conditions, material alloying elements and heat treatment. The DER, WEB and butterfly formations are well studied in two dimensions (2D). The objective of this study was to analyze WEB formation in three dimensions (3D) that will allow better understanding of material transformation after stress cycling. Three rolling contact fatigue (RCF) tested vacuum induction melted vacuum arc re-melted (VIM-VAR) AISI M50 samples (from a bench test, sub-scale test and commercial gas turbine engine) were analyzed using automated serial sectioning to map WEB networks and a butterfly formation in 3D. Automated serial sectioning and 2D optical microstructural data for 3D reconstructions and analysis was done using a fully automated serial sectioning system – Robo-Met.3D®. 3D analysis was performed using Image-Pro Premier 3D. The data set allowed 3D visualization and analysis of the evolution and propagation of WEB and butterfly in M50 bearing steel, including the positive microscopic identification of a ceramic inclusion that was the source of a WEB.

36 MATERIALS SCIENCE↗