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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 OSTI2024

Evaluation of Corrosion and Its Impact on the Mechanical Performance of Al–Steel Joints

Aluminum–steel joints are increasingly used in the automotive industry to meet the requirements for energy saving and emission reduction. Among various joining technologies, self-pierce riveting (SPR) and resistance spot welding (RSW) are two well-established technologies for fabricating dissimilar joints with stable and high mechanical performance. However, corrosion will occur in these joints inevitably due to different electrochemical properties, which can degrade the surface quality and the mechanical performance, such as strength. This paper presents a method of understanding the corrosion mechanisms in joining aluminum and steel. For this understanding, a hybrid method combining experimental observations, mechanical properties identification, and analytical approaches was used to assess the evolution of the impact of corrosion on the joining performance, such as traction separation curves. The study was conducted on common combinations used in the vehicles, e.g., a 1.2 mm thickness aluminum alloy (AA 6022) and 2.0 mm thickness hot deep galvanized steel (HDG HSLA 340) joined by SPR and RSW. After the fabrication of these joints, accelerated cyclic corrosion tests of up to 104 cycles were performed, which reproduced the environmental conditions to which a vehicle was exposed. By investigating the microstructural evolution within the joints, the corrosion mechanisms of SPR and RSW joints were revealed, including the initiation and propagation. Moreover, the intrinsic impact of the corrosion on the mechanical performance, including the strength, axial stiffness, and crashworthiness, was analyzed by performing a lap-shear test. It showed that as corrosion proceeds, the fracture modes and mechanical performance are affected significantly.

Chemistry↗
DOE OSTI2025

High-Temperature Neutron Diffraction Study of Vanadium and Vanadium–Niobium Null-Matrix Alloy for Spectrum Normalization

This study systematically evaluates a vanadium–niobium (V 94.1 Nb 5.9 ) null-matrix alloy as a reference material for neutron spectrum normalization and compares its performance with that of pure vanadium under identical experimental conditions. Neutron diffraction experiments are conducted on the VULCAN Engineering Materials Diffractometer at the Spallation Neutron Source, Oak Ridge National Laboratory, over a temperature range from room temperature to 1200 °C under vacuum. Pure vanadium exhibited distinct Bragg peaks across all temperatures, with its diffraction behavior influenced by both sample orientation and temperature. As the temperature increased, the diffraction peaks shifted to larger d-spacings and decreased in intensity, while spectral deviation near d ≈ 2.8 Å exceeded 10% at 1200 °C. In contrast, the V–Nb alloy produced a nearly featureless spectrum over the full d-spacing range, confirming near-complete cancellation of coherent scattering over the wide temperature range. Its spectra were insensitive to sample orientation, temperature, and microstructural evolution, with spectral deviation around d ≈ 2.8 Å exceeded 5% at 1200 °C. In conclusion, these results demonstrate that the V–Nb null-matrix alloy provides a thermally stable, efficient, and reliable normalization standard for time-of-flight diffractometers or other instrument where it is needed, enabling reduced data acquisition time and improved data quality in high-temperature neutron diffraction experiments.

Alloys↗
DOE OSTI2019

Consideration of Thermal Embrittlement in Alloy 316H for Advanced Non-Light Water Reactor Applications

To construct advanced non-light water reactors (ANLWRs) operating in the temperature range above that for the traditional light water reactors (LWRs), Alloy 316H is one of the candidate materials because of its inexpensiveness, significant service experience, and qualification for nuclear applications by the American Society of Mechanical Engineers (ASME). However, during the life span at temperatures expected for the ANLWRs, the alloy is likely to experience thermal embrittlement that has not been a concern for the traditional LWRs. To prepare for the development, the possibility of adverse thermal embrittlement effects on Alloy 316H performance in the ANLWRs must be evaluated and a technical basis regarding thermal embrittlement, if necessary, must be established for structural integrity analysis to provide reasonable assurance of adequate nuclear safety protection.In this paper, current technical basis for nuclear applications of Alloy 316H deterioration from thermal aging is briefly introduced. The likelihood of adverse thermal embrittlement effects on Alloy 316H performance is evaluated through historical data on microstructural and mechanical property evolution. Characterization of thermal embrittlement is then discussed, followed by a review of predictive models and trend curves for alloy embrittlement. Based on the review and evaluation, technical gaps for addressing thermal embrittlement issues are identified and gap-filling actions are recommended for establishing a technical basis to enable adequate consideration of thermal embrittlement in Alloy 316H applications to the ANLWRs.

Ren, Weiju↗
DOE OSTI2021

Fracture Mechanics—Theory, Modeling and Applications

The field of fracture mechanics was developed during the throes of World War II, and since then, it has been a very active area of research. This is a very energetic and vibrant field because fracture processes are relevant for a vast range of engineering applications spanning different temporal and length scales. Depending on the application, material fracture and fragmentation may be either a desirable feature (for example, for the purpose of hydraulic fracturing operations), or something that is to be avoided at all costs (for example, in key components of mechanical systems). In some other instances, fractures are already present and must be accommodated through novel design (for example, in the case of earthquake ruptures occurring in the Earth’s crust). Because of this wide spectra of motivation, there is a continuous need for the fracture mechanics research community to gain more insight on how fractures are created, evolve, and interact with themselves and with material microstructures. In addition, there are still many remaining questions about how fracture propagation, growth, and interaction impact overall material behavior, and how to develop accurate models to predict this behavior.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Novel mechanisms for solid-state processing and grain growth with microstructure alignment in alnico-8 based permanent magnets

An estimated 750,000 new hybrid electric and plug-in battery vehicles, most with permanent magnet synchronous alternating current (PMAC) drive motors, took to the road in 2016 alone. Accompanied by 40% year over year growth in the EV market significant challenges exist in producing large quantities of permanent magnets (on the order of tens of millions) for reliable, low-cost traction motors [IE Agency, Energy Technology Perspectives (2017)]. Since the rare earth permanent magnet (REPM) market is essentially 100% net import reliant in the United States and has proven to have an unstable cost and supply structure in recent years, a replacement RE-free PM material must be designed or selected, fully developed, and implemented. Alnico, with its high saturation magnetization and excellent thermal stability, appears to be uniquely suited for this task. Further, while alnico typically has been considered a relatively low coercivity hard magnet, strides have been made to increase the coercivity to levels suitable for traction drive motors [W Tang, IEEE Trans. Magn., 51 (2015)]. If a simple non-cast approach for achieving near [001] easy axis grain aligned permanent magnets can be found, this would allow massproduced final-shape anisotropic high energy product magnets suitable for usage in compact high RPM rotor designs. Therefore, a powder metallurgical approach is being explored that uses classic compression molding with “de-bind and sinter” methods, where a novel applied uniaxial loading, and an applied magnetic field may create final-shape magnets with highly textured resulting microstructures by two different mechanisms. Results indicate a positive correlation between applied uniaxial load and resulting texture (Fig. 1), along with benefits from using an applied magnetic field for improved texture, as well. Lastly, the apparent mechanisms and resulting properties will be described using closed loop hysteresisgraph measurements, EBSD orientation mapping, and high-resolution SEM.

42 ENGINEERING↗
DOE OSTI2017

Superconducting Thin Films for The Enhancement of Superconducting Radio Frequency Accelerator Cavities

Bulk niobium (Nb) superconducting radio frequency (SRF) cavities are currently the preferred method for acceleration of charged particles at accelerating facilities around the world. However, bulk Nb cavities have poor thermal conductance, impose material and design restrictions on other components of a particle accelerator, have low reproducibility and are approaching the fundamental material-dependent accelerating field limit of approximately 50MV/m. Since the SRF phenomena occurs at surfaces within a shallow depth of ~1 μm, a proposed solution to this problem has been to utilize thin film technology to deposit superconducting thin films on the interior of cavities to engineer the active SRF surface in order to achieve cavities with enhanced properties and performance. Two proposed thin film applications for SRF cavities are: 1) Nb thin films coated on bulk cavities made of suitable castable metals (such as copper or aluminum) and 2) multilayer films designed to increase the accelerating gradient and performance of SRF cavities. While Nb thin films on copper (Cu) cavities have been attempted in the past using DC magnetron sputtering (DCMS), such cavities have never performed at the bulk Nb level. However, new energetic condensation techniques for film deposition, such as High Power Impulse Magnetron Sputtering (HiPIMS), offer the opportunity to create suitably thick Nb films with improved density, microstructure and adhesion compared to traditional DCMS. Clearly use of such novel technique requires fundamental studies to assess surface evolution and growth modes during deposition and resulting microstructure and surface morphology and the correlation with RF superconducting properties. Here we present detailed structure-property correlative research studies done on Nb/Cu thin films and NbN- and NbTiN-based multilayers made using HiPIMS and DCMS, respectively. Experiment Numbers:

Burton, Matthew↗
DOE OSTI2022

The kinetics of static recovery by dislocation climb

Abstract The initial microstructure of a wide range of structural materials is conditioned by thermo-mechanical treatments such as hot-working, tempering, or solution annealing. At the elevated temperatures associated with these treatments the dislocation microstructure evolves, usually decreasing in density through a process known as static recovery. Despite its technological relevance, static recovery is not fully characterized from a theoretical standpoint, with even the controlling mechanisms subject to debate. In this study, a climb-enabled discrete dislocation dynamics (DDD) capability is leveraged to explore the kinetics of static recovery in pure Fe when controlled by dislocation climb. Quantitative data from these simulations is used to develop a revised static recovery law, and provides the parameters appropriate for predictive microstructure models in Fe. This law differs from previous analytical derivations invoking climb of dislocations, following the logarithmic trends typical of experimental observations where prior work did not. Direct comparison between the recovery law derived from DDD to experimental recovery data in alpha Fe shows strong agreement across a range of temperatures, and suggests that climb is the controlling mechanism for static recovery in pure metals.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Spherical Nanoindentation Stress-Strain Measurements of BOR-60 14YWT-NFA1 Irradiated Tubes

Spherical nanoindentation stress-strain protocols were applied to characterize unirradiated and fast neutron irradiated nanostructured ferritic alloy (NFA) 14YWT and compared against Berkovich nanohardness and available tensile data. The predicted uniaxial yield strength from spherical, 100 and 5 micron radii, indentation yield strength measurements was 1100-1400 MPa which compares well with the predictions from Berkovich nanohardness, 1200 MPa, and available tensile data, ~1100 MPa. However, spherical indentation measurements predict an increase in the uniaxial yield strength of ~1 GPa while Berkovich nanohardness measurements predict an increase of only ~250 MPa. No tensile data exists on the irradiated condition. It is believed the difference in the predicted uniaxial yield strength between spherical and Berkovich nanoindentation are due to a low number of tests on the irradiated sample combined with the significant heterogeneity in the microstructure, the differences in sensitivity to sample preparation on the irradiated sample between the two indentation protocols , and/or in how strain localizes under the indenter with the possibility of dislocation channeling under Berkovich hardness indents leading to strain softening. Nanoindentation capabilities to test neutron irradiated samples in a radiological area were realized.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Effect of pore fluid chemistry on the mechanical behavior of a divalent compacted bentonite, an experimental and constitutive study

Ongoing research in isolating high-level nuclear waste and spent fuel has highlighted compacted bentonite as a suitable material for engineered barrier systems in deep geological repositories due to its extraordinary swelling and retention properties. This research focuses on the chemo-mechanical behavior of compacted bentonite exposed to different pore fluids with different concentrations and loading conditions. The study involves swelling pressure and compressibility experiments along with mineralogy analysis employing X-ray diffraction (XRD) and Cation exchange. The tests were conducted on BCV (a Mg/Ca- bentonite) compacted at a dry density of 1.48 ± .02 Mg/m 3 . An advanced chemical-mechanical constitutive model for unsaturated highly expansive clays was adopted to simulate the material response and better understand its behavior. The model is able to account for the main phenomena at both macro and microstructural levels and the interactions between them. The model successfully replicated experimental observations. The XRD analyses support the macroscopic observation, indicating that salinity impacts crystalline swelling as demonstrated by the reduction of basal spacing from 19.27 Å to 15.68 Å when the osmotic suction increases from 0 MPa to 33 MPa. The results suggested that the osmotic pressure generated by the concentration in the pore fluids promotes a reduction in swelling pressures, swelling strains, and crystalline swelling of clay minerals. Also, it affects the pre-consolidation stress and the compressibility of the compacted samples. In conclusion, it was also observed that both solution type and solution concentration impact the clay swelling pressure.

Chemo-mechanical constitutive model↗
DOE OSTI2020

Investigating the effect of different shielding gas mixtures on microstructure and mechanical properties of 410 stainless steel fabricated via large scale additive manufacturing

Metal Big Area Additive Manufacturing (mBAAM) offers the potential to fabricate large scale tools at high deposition rates (15 lb/h+). 410 martensitic steel is a potential tooling material, owing to its low cost, good machinability and reasonable printability. During the mBAAM process, the shielding gas can have a significant impact on the material properties as well as the process cost. Therefore, the current study aims to understand the effect of different shielding gas mixtures on large-scale additive manufacturing of 410 martensitic stainless steel. We show that an argon mixture with 3% nitrogen gas produced the best performance in terms of maximum hardness and tensile strength, with much less scatter in tensile strength. He-Ar-CO 2 or tri-mix shielded samples showed a low tensile strength with wide scatter, due to stabilized delta ferrite in microstructure during printing. Both tri-mix and Ar-CO 2 shielded samples showed slightly higher porosity. Thus, we recommend the use of argon-3% nitrogen as a shielding gas mixture for processing 410 steel for tool applications, based on the relatively low cost of this gas mixture and the resulting higher hardness, higher dimensional stability, and lower porosity.

36 MATERIALS SCIENCE↗
DOE OSTI2023

A combined experimental and crystal plasticity study of grain size effects in magnesium alloys

This work presents a method to incorporate the micro Hall-Petch equation into the crystal plasticity finite element (CPFE) framework accounting for the microstructural features to understand the coupling between grain size, texture, and loading direction in magnesium alloys. The effect of grain size and texture is accounted for by modifying the slip resistances of individual basal and prismatic systems based on the micro Hall-Petch equation. The modification based on the micro Hall-Petch equation endows every slip system at each microstructural point with a slip system-level grain size and maximum compatibility factor, which are in turn used to modify the slip resistance. While the slip-system level grain size is a measure of the grain size, the maximum compatibility factor encodes the effect of the grain boundary on the slip system resistance modification and is computed based on the Luster-Morris factor. The model is calibrated using experimental stress-strain curves of Mg-4Al samples with three different grain sizes from which the Hall-Petch coefficients are extracted and compared with Hall-Petch coefficients predicted using original parameters from previous work. The predictability of the model is then evaluated for a Mg-4Al sample with different texture and three grain sizes subjected to loading in different directions. The calibrated parameters are then used for some parametric studies to investigate the variation of Hall-Petch slope for different degrees of simulated spread in basal texture, variation of Hall-Petch slope with loading direction relative to basal poles for a microstructure with strong basal texture, and variation of yield strength with change in grain morphology. The proposed approach to incorporate the micro Hall-Petch equation into the CPFE framework provides a foundation to quantitatively model more complicated scenarios of coupling between grain size, texture and loading direction in the plasticity of Mg alloys.

Crystal plasticity↗
DOE OSTI2018

Origin of dielectric relaxor behavior in PVDF-based copolymer and terpolymer films

Relaxor ferroelectrics exhibit frequency-dispersion of their dielectric permittivity peak as a function of temperature, the origin of which has been widely debated. Microscopic understanding of such behavior for polymeric ferroelectrics has presented new challenges since unlike traditional ceramic ferroelectrics, dielectric relaxation in polymers is a consequence of short-range molecular dynamics that are difficult to measure directly. Here, through careful analysis of atomic-level H-atom dynamics as determined by Quasi-elastic Neutron Scattering (QENS), we show that short-range molecular dynamics within crystalline domains cannot explain the macroscopic frequency-dispersion of dielectric properties observed in prototypical polyvinylidene-fluoride (PVDF)-based relaxor ferroelectrics. Instead, from multiscale quantitative microstructural characterization, a clear correlation between the amount of crystalline-amorphous interfaces and dielectric relaxation is observed, which indicates that such interfaces play a central role. These results provide critical insights into the role of atomic and microscopic structures towards relaxor behavior in ferroelectric polymers, which will be important for their future design.

42 ENGINEERING↗
DOE OSTI2020

Abstract for CRADA between the National Energy Technology Laboratory and General Motors (AGMT-0876)

Lightweight aluminum shape castings have widespread applications for structural components in the automotive, aerospace, and general engineering industries because of their excellent castability, corrosion resistance, and particularly high strength-to-weight ratio in the heat-treated condition. In the automotive industry, cast aluminum alloys have been increasingly used to replace cast iron and steel in vehicle applications such as engine blocks, cylinder heads, intake manifolds, brackets, housings, chassis, transmission parts, and suspension systems to reduce mass. As many of the aluminum shape castings used in automobiles involve cyclic loading, fatigue properties of the castings are critical to their success. The increasing use of lightweight aluminum cast components in critical structures thus requires improved integrity, with more reliable and quantifiable performance. The objective of this project is to demonstrate and further develop GM’s patent-pending, novel casting process, “Pressure-Assistant Precision Sand Casting (PAPSC) for producing flawless cast aluminum cylinder heads with minimum manufacturing and energy costs”. The approach is to leverage NETL’s experience in producing high-quality metal castings through various microstructure control and defect elimination technologies as well as comprehensive quantification of microstructure characteristics and mechanical properties. A baseline (production) alloy together with the melt treatment will be initially evaluated with the new PAPSC process to develop and validate the process window for producing flawless cast aluminum heads.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Anisotropic contraction of fiber-reinforced hydrogels

Hydrogels reinforced by fibers can undergo remarkable anisotropic contraction triggered by external stimuli, which has a broad appeal for various applications. However, little is known about how to optimize the contraction anisotropy by tuning the microstructures of fiber-reinforced hydrogels. Here, we investigate the underlying mechanisms controlling the anisotropic contraction of fiber-reinforced hydrogels. Using a simplified model incorporating the directional constraint of the fibers, we show that the contraction anisotropy can be substantially enhanced if the hydrogel is prestretched along the fiber direction. We further explicitly model fibers as periodically distributed cylindrical rods in the finite element simulations, and find that the contraction anisotropy can be maximized by varying the transverse fiber–fiber distance; this maximum anisotropy can be improved by reducing the longitudinal fiber–fiber distance and increasing the fiber length. Our study provides insights into designing novel fiber-reinforced hydrogels, suggesting possible applications in soft robotics, tissue engineering and beyond.

catalysis (homogeneous), solar (photovoltaic), bio↗
DOE OSTI2025

An engineering perspective on evaluating mechanisms governing ductility in pure molybdenum

The United States lacks a stable domestic supply of 99 mTc, a critical medical imaging isotope generated from 99 Mo. Accelerator-based production using 100 Mo targets (aMo) introduces mechanical concerns due to the ductile-to-brittle transition temperature inherent to refractory metals like Mo. This study evaluates the tensile behavior of aMo targets from 25 to 1000 °C, compared to powder-metallurgy-processed natural Mo (PMo) and cast-and-rolled Mo (RMo), both as-received and after 5 ppm O 2 exposure in flowing He. RMo showed superior ductility (7.3% at 25 °C, 48% at 1000 °C) and strength, attributed to its fine, elongated grains and high geometrically necessary dislocation density. PMo exhibited variable ductility (up to 33%), while aMo remained brittle, with a maximum elongation of 10.4% at 600 °C. EBSD analysis revealed weak texture in PMo and aMo, but high defect density in aMo limited dislocation mobility. This work links processing, microstructure, and deformation mechanisms to guide fabrication of ductile refractory targets.

Hyer, Holden C. [Oak Ridge National Laboratory (OR↗
DOE OSTI2019

Dopant-Dependent Increase in Seebeck Coefficient and Electrical Conductivity in Blended Polymers with Offset Carrier Energies

The strong and counterproductive interrelationship of thermoelectric parameters remains a bottleneck to improving thermoelectric performance, especially in polymer-based materials. In this paper, we decouple the electrical conductivity and Seebeck coefficient, achieving increases in at least one of these two parameters while the other is maintained or slightly increased as well. This is done using an alkylthio-substituted polythiophene (PQTS12) as additive in poly(bisdodecylquaterthiophene) (PQT12) with tetrafluorotetracyanoquinodimethane (F4TCNQ) and nitrosyl tetrafluoroborate (NOBF4) as dopants. The power factor increased two orders of magnitude with the PQTS12 additive at constant doping level. Using a second pair of polymers, poly(2,5-bis(3-dodecylthiophen-2-yl)thieno[3,2-b]thiophene (PBTTTC12) and poly(2,5-bis(3-dodecylthiothiophen-2-yl)thieno[3,2-b]thiophene, (PBTTTSC12), with higher mobilities, we also observed the decoupling of the Seebeck coefficient and electrical conductivity, and achieved higher power factor. Distinguished from recently reported works, these two sets of polymers possess very closely offset carrier energy levels (0.05 ~ 0.07 eV), and the microstructure, assessed using grazing incidence X-ray scattering, and mobility evaluated in field-effect transistors, was not adversely affected by the blending. Experiments, calculations and simulations are consistent with the idea that blending and doping polymers with closely-spaced energy levels and compatible morphologies to promote carrier mobility favors increased power factors.

42 ENGINEERING↗
DOE OSTI2023

Electromagnetic levitation containerless processing of metallic materials in microgravity: rapid solidification

Space levitation processing allows researchers to conduct benchmark tests in an effort to understand the physical phenomena involved in rapid solidification processing, including alloy thermodynamics, nucleation and growth, heat and mass transfer, solid/liquid interface dynamics, macro- and microstructural evolution, and defect formation. Supported by ground-based investigations, a major thrust is to develop and refine robust computational tools based on theoretical and applied approaches. This work is accomplished in conjunction with experiments designed for precise model validation with application to a broad range of industrial processes.

42 ENGINEERING↗
DOE OSTI2024

Identifying Heterogeneous Micromechanical Properties of Biological Tissues via Physics–Informed Neural Networks

The heterogeneous micromechanical properties of biological tissues have profound implications across diverse medical and engineering domains. However, identifying full-field heterogeneous elastic properties of soft materials using traditional engineering approaches is fundamentally challenging due to difficulties in estimating local stress fields. Recently, there has been a growing interest in data-driven models for learning full-field mechanical responses, such as displacement and strain, from experimental or synthetic data. However, research studies on inferring full-field elastic properties of materials, a more challenging problem, are scarce, particularly for large deformation, hyperelastic materials. Here, a physics-informed machine learning approach is proposed to identify the elasticity map in nonlinear, large deformation hyperelastic materials. This study reports the prediction accuracies and computational efficiency of physics-informed neural networks (PINNs) in inferring the heterogeneous elasticity maps across materials with structural complexity that closely resemble real tissue microstructure, such as brain, tricuspid valve, and breast cancer tissues. Further, the improved architecture is applied to three hyperelastic constitutive models: Neo-Hookean, Mooney Rivlin, and Gent. Furthermore, the improved network architecture consistently produces accurate estimations of heterogeneous elasticity maps, even when there is up to 10% noise present in the training data.

59 BASIC BIOLOGICAL SCIENCES↗