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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 1,009 records · Page 56
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Isothermal annealing behaviour of nuclear grade 20Cr-25Ni austenitic stainless steel

Highlights: • At 930 °C recrystallisation of deformed 20/25 Nb steel is completed after 120 s. • Recrystallisation proceeds by strain induced boundary migration. • An increase of cube oriented grains at the expense of S oriented is observed. • The boundary migration induced the precipitation of niobium carbides. • The grain size is limited by the particle dispersion according to Zener pinning. - Abstract: We have performed an in-depth characterisation of the microstructure evolution of 20Cr-25Ni Nb-stabilised austenitic stainless steel during isothermal annealing at 930 °C using scanning and transmission electron microscopy. This steel grade is used as cladding material in advanced gas-cooled fission reactors, due to its resistance to thermal creep and water corrosion. The initial deformed microstructure undergoes recrystallisation via a strain-induced boundary migration mechanism, attaining a fully recrystallised microstructure after 120 s of annealing. The transition from low-to-high grain boundaries has already occurred after 15 s, together with an increase in the cube grain orientation at the expense of the S texture component. After 120 s, the grain boundary migration induces the formation of new fine Nb(C,N) particles, whereas the pre-existing particles become enriched in Ni and Si. The resulting particle population limits the grain growth in the austenitic matrix, based on the Zener pinning model, resulting in relatively small recrystallised austenite grains and a high density of high-angle and special coincidence-lattice-site grain boundaries, together with a large number of particle/matrix interfaces.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Phase-Field Modeling of Thermally-Grown Oxide and the Induced Damage Evolution in Environmental Barrier Coatings

The advent of next-generation hydrogen-based engines necessitates materials capable of withstanding temperatures beyond the reach of current superalloys. SiC-based ceramic matrix composites, augmented with environmental barrier coatings (EBCs), present a promising materials solution. Given the active search for effective and durable EBCs, there is a pressing need for modeling tools to understand and predict damage evolution in these materials to help accelerate their development. This study introduces a phase-field model (PFM) designed to simulate the critical role of thermally grown oxides (TGO) in the degradation and failure of EBCs. The model accounts for the severe volume expansion due to oxidation, alongside phase transformations and microstructural evolution during thermal cycling, offering a comprehensive view of the damage processes. Simulation results are validated against experimental findings reported in the literature, establishing the model's potential as a significant tool for understanding and improving the resilience of EBCs in cyclic oxidative environments.

Cheng, Tianle↗
DOE OSTI2013

Microstructural and textural evolution of AZ61 magnesium alloy sheet during bidirectional cyclic bending

In this work, the microstructural and textural evolution in the sheets of AZ61 magnesium alloy was studied by means of bidirectional cyclic bending for 8 passes at 623 K. The bended samples were examined by optical microscopy and electron backscatter diffraction analysis. The results showed that a gradient structure with fine grains about 3 μm in the regions near two surfaces and, in contrast, coarse grains in the middle of the sheet were formed. The evident grain refinement was attributed to twin-assisted dynamic recrystallization and continuous dynamic recrystallization induced by kink bands. The texture intensity was clearly reduced, resulting in a negative gradient distribution, with the texture intensity decreases from the center of the sheet to two surfaces. The weakened texture greatly facilitated the reduction of the yield strength. A higher fracture elongation and a slightly improved ultimate tensile strength were achieved concurrently. - Highlights: • The AZ61 Mg alloy is deformed at 623 K by bidirectional cyclic bending. • A symmetric gradient distribution of fine grains along the thickness is formed. • The basal texture in the regions near two surfaces is weakened significantly.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Characterization of Static Recrystallization of a Ni-Cr-Mo-Based C276 Superalloy in Two-Stage Isothermal Compression

In order to clarify the microstructure evolution characteristics during holding period after slight degree of deformation for a Ni-Cr-Mo-based C276 superalloy, two-stage isothermal compression tests have been performed at the temperature range of 1000-1150 °C and the strain rate range of 0.1-5 s{sup −1}. The stress–strain curves and microstructure observation infer that both static recovery (SRV) and static recrystallization (SRX) took place during the holding period when the specimens were deformed at 1100-1150 °C and only SRV occurred in the specimens that deformed at the temperatures lower than 1100 °C. The softening effects increase with the increasing temperature and deformation degree, while the influence of strain rate seems less pronounced because of the limited stored energy resulted from the small deformation. The grain boundary characteristics, analyzed using electron backscatter diffraction technique, indicate that high densities of twins and Σ3 grain boundaries form associated with the nucleation and growth of SRX grains. Finally, the recrystallization during and after deformation, i.e., dynamic recrystallization, SRX and metadynamic recrystallization, was discussed concurrently.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Cascading microstructures in aluminum-steel interfaces created by impact welding

With the rising need to develop light weight structures joining dissimilar metals is inevitable. Thus a fundamental understanding of the microstructure evolution and bond formation mechanism is necessary. In this work we probe the welded interface in aluminum and steel joined using vaporizing foil actuator welding (VFAW) a novel impact welding process. The goal of such a detailed characterization campaign is to understand the bond formation mechanism. The study demonstrates that the interfacial microstructure has a pronounced hierarchical nature. At the macro scale, the interface is characterized by a wavy interface which is a result of extensive plastic deformation that accompanies the process. Detailed transmission electron microscopy shows evidence for the formation of a liquid film at the interface resulting in significant inter diffusion of Fe. The solidified structure at the interface consisted of crystalline α-Al and an amorphous metastable Al-Fe intermetallic compound similar to the observations in rapid solidification of Al-Fe alloys. The sub-nm scale characterization of the interface using atom probe tomography showed two distinct zones 1. A magnesium (5 at.%) and oxygen (15 at.%) rich (not detectable using energy dispersive spectroscopy) which was probably from the decomposition of the surface oxide film 2. The rapidly solidified reaction zone consisting of primary crystalline α-Al and an amorphous Al-Fe (15 at.%)-O (0.5 at.%)-Si (1.5 at.%).Based on these observations a mechanism for the bond formation is presented.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Effects of chemistry and microstructure on corrosion performance of Zircaloy-2-based BWR cladding - 2016-0066

In boiling water reactors (BWRs), Zircaloy-2 is typically the material of choice for fuel cladding. With increased focus on fuel performance and reliability, consistent cladding corrosion performance under varying BWR conditions has become an acknowledged requirement for modern BWR fuel. To support optimization of corrosion performance, modifications to alloy chemistry and manufacture conditions can be made, supported by ex-reactor corrosion testing and demonstrated through in-reactor operation. In this work, the combined effects of alloy chemistry and fabrication process were investigated. The effect of alloy chemistry is often complicated by variation within a production ingot. In this work, additional measurements were intentionally taken at the tube-shell stage (before cold pilgering) so that chemistry more representative of the final cladding could be obtained and the effect of iron, nickel, and tin could be examined more closely. Although chemistry range of Zircaloy-2 was the primary focus, the effect of iron above the ASTM limit in a new alloy was also explored. Three types of cladding fabrication processes were considered. Two types included a heat treatment applied after the first cold pilgering and annealing, and the treatment was limited to the outer portion of the cladding and differed in the temperature of the heat treatment; the third type had no special heat treatments after the first cold pilgering and annealing. The weight gain of the three types of cladding with varying compositions under two corrosion test conditions (400 deg. C steam and 410/520 deg. C two-stage steam) are discussed in terms of the initial second-phase particle sizes obtained from transmission electron microscopy examinations. Based on poolside inspections and hot-cell examinations, the in-reactor corrosion performance of the two cladding types up to typical discharge exposures are discussed in the terms of corrosion margin, microstructure evolution, and correlation with ex-reactor corrosion test data. (authors)

36 MATERIALS SCIENCE↗
DOE OSTI2013

Mechanical Properties of Nuclear Fuel Surrogates using Picosecond Laser Ultrasonics

Detailed understanding between microstructure evolution and mechanical properties is important for designing new high burnup nuclear fuels. In this presentation we discuss the use of picosecond ultrasonics to measure localize changes in mechanical properties of fuel surrogates. We develop measurement techniques that can be applied to investigate heterogeneous elastic properties caused by localize changes in chemistry, grain microstructure caused by recrystallization, and mechanical properties of small samples prepared using focused ion beam sample preparation. Emphasis is placed on understanding the relationship between microstructure and mechanical properties

25 ENERGY STORAGE↗
DOE OSTI2024

Phase-field modeling for restructuring in the dark zone of high burnup UO 2

This report summarizes the mesoscale modeling work performed in fiscal year 2024 under the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program to capture the microstructural evolution and restructuring observed in the dark regions of high burnup UO 2 nuclear fuel. This is the first attempt to realistically simulate the restructuring behavior observed in different region of a high burnup fuel. We employ a grand-potential based phase-field model to concurrently evaluate the formation of subgrains and growth of fission bubbles within the fuel. A energy-based subgrain formation criteria is introduced to simulate the restructuring process. Effect of different initial conditions and different modeling parameters are studies systematically to capture how each of these parameters influence the characteristics of the restructured fuel. It is observed that the subgrain formation begins around existing fission gas bubbles and then proceeds towards triple junctions, grain boundaries and grain interiors. It is demonstrated that restructuring is influenced by a combination of initial dislocation densities, subgrain formation rate, and temperature. Rate of restructuring increases with increase in fuel temperature. A restructuring bias is observed within the microstructure due to variation in defect accumulation among different grains. Furthermore, bubble sizes and distribution does not have a significant effect on rate of restructuring. The predicted microstructures resembles the characteristics of the restructured regions as observed in experiments. Finally, a correlation is presented that demonstrates the evolution of the restructuring volume fraction as a function of local effective burnup. This work provides a first of its kind restructuring model for darkzone that can be used by BISON for performance prediction of high burnup UO 2 fuel.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2017

The Effects of Specimen Geometry on the Plastic Deformation of AA 2219-T8 Aluminum Alloy Under Dynamic Impact Loading

The effects of specimen geometry on shear strain localization in AA 2219-T8 aluminum alloy under dynamic impact loading were investigated. The alloy was machined into cylindrical, cuboidal and conical (frustum) test specimens. Both deformed and transformed adiabatic shear bands developed in the alloy during the impact loading. The critical strain rate for formation of the deformed band was determined to be 2500 s{sup −1} irrespective of the specimen geometry. The critical strain rate required for formation of transformed band is higher than 3000 s{sup −1} depending on the specimen geometry. The critical strain rate for formation of transformed bands is lowest (3000 s{sup −1}) in the Ø5 mm × 5 mm cylindrical specimens and highest (> 6000 s{sup −1}) in the conical specimens. The cylindrical specimens showed the greatest tendency to form transformed bands, whereas the conical specimen showed the least tendency. The shape of the shear bands on the impacted plane was also observed to be dependent on the specimen geometry. Whereas the shear bands on the compression plane of the conical specimens formed elongated cycles, two elliptical shaped shear bands facing each other were observed on the cylindrical specimens. Two parallel shear bands were observed on the compression planes of the cuboidal specimens. The dynamic stress–strain curves vary slightly with the specimen geometry. The cuboidal specimens exhibit higher tendency for strain hardening and higher maximum flow stress than the other specimens. The microstructure evolution leading to the formation of transformed bands is also discussed in this paper.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Polycrystal Plasticity: Comparison Between Grain - Scale Observations of Deformation and Simulations

Here, the response of polycrystals to plastic deformation is studied at the level of variations within individual grains, and comparisons are made to theoretical calculations using crystal plasticity (CP). We provide a brief overview of CP and a review of the literature, which is dominated by surface observations. The motivating question asks how well does CP represent the mesoscale behavior of large populations of dislocations (as carriers of plastic strain). The literature shows consistently that only moderate agreement is found between experiment and calculation. We supplement this with a current example of microstructure evolution in the interior of a copper sample subjected to tensile deformation. Nondestructive measurements of orientation fields were performed using the near-field high-energy X-ray diffraction microscopy (nf-HEDM) technique at the Advanced Photon Source (APS). Starting at highly ordered grains, a single two-dimensional slice of microstructure containing ~150 grains was followed through multiple strain states, where it tracked lattice rotations and defect accumulation of up to 14% elongation. In accord with the literature, at the scale of individual grains, comparison of observations with CP models indicates reasonable qualitative agreement but significant variations between simulation and experiment are apparent. The conclusion is that in order to be able to quantify the effects of microstructure on the distributions of slip, orientation change, and damage accumulation, the empirically derived constitutive relations used in continuum-scale simulations need to be improved. Equally important will be the development of large-scale simulations of polycrystals that directly model dislocations.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Evolution of dislocation substructures in metals via high-strain-rate nanoindentation

Deformation at high strain rates often results in high stresses on many engineering materials, potentially leading to catastrophic failure without proper design. High-strain-rate mechanical testing is thus needed to improve the design of future structural materials for a wide range of applications. Although several high-strain-rate mechanical testing techniques have been developed to provide a fundamental understanding of material responses and microstructural evolution under high-strain-rate deformation conditions, these tests are often very time consuming and costly. In this work, we utilize a high-strain-rate nanoindentation testing technique and system in combination with transmission electron microscopy to reveal the deformation mechanisms and dislocation substructures that evolve in pure metals from low (10 –2 s –1 ) to very high indentation strain rates (10 4 s –1 ), using face-centered cubic aluminum and body-centered cubic molybdenum as model materials. The results help to establish the conditions under which micro- and macro-scale tests can be compared with validity and also provide a promising pathway that could lead to accelerated high-strain-rate testing at substantially reduced costs.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Radiation damage of a two-dimensional carbon fiber composite (CFC)

Carbon fiber composites (CFC) are, among other applications, already in use as low-impedance collimating elements for intercepting TeV-level protons machines, like the CERN Large Hadron Collider. Towards a comprehensive understanding of these materials’ properties and behavior, a series of radiation damage campaigns have been undertaken in order to quantitively investigate the response of AC-150 K CFC to high proton fluences. The CFCs dimensional changes, stability, micro-structural evolution, and structural integrity below and above 5 × 10 20 p/cm 2 fluence threshold were studied. The irradiating particles were protons of kinetic energies in the range of 130–200 MeV. The effects of the irradiation temperature (~90–180°C and 280–500°C) combined with the proton fluence on the dimensional stability and the microstructural evolution of this anisotropic two-dimensional composite structure were studied using precision dilatometry and X-ray diffraction. Our results shed light on the fluence-based limitations for these composite materials. Furthermore, we compare these results with reference unirradiated graphite, and we discuss the similarities and differences in the dimensional changes and post-irradiation annealing properties.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Mirostructure Characterization of Friction Consolidated Copper-Nickel using a Machine Learning Approach: Developing Process to Microstructure Associations

Friction consolidation (FC) is a solid phase processing approach where discrete material forms such as powders, chips, nuggets, etc. are densified via shear deformation. The precursors are placed in a billet container and brought in contact with a rotating tool that applying the desirable amount of normal force. Under the combined action of the rotation and normal pressure, the discrete precursor is consolidated through porosity reduction and shear deformation. FC is increasingly being studied as an attractive approach to manufacturing fully dense parts from powder forms owing to its ability to mix, alloy and consolidate difficult-to-process precursors in minimal number of process steps. Material consolidation and deformation in shear consolidation processes have been studied extensively previously for different material combinations previously. However, despite the extensive research in this area, understanding of the mechanistic processes in pore consolidation, deformation-induced mixing and material solubility during FC is still evolving. Material development using solid phase processing approaches such as FC is often performed based on research experience/education, which can be biased. Conventional analysis and simulation tools in this area tend to be successful only when material thermodynamic pathways and microstructural evolution sequences resulting from processing are clearly defined or known. They are not as effective for emerging advanced manufacturing technologies where material evolution pathways are not well established. The ability to predict optimal process parameters based on material chemistry and bulk properties is essential to accelerate materials design and processing, as are an understanding of the relevant structure-processing-property relationships. These structure-processing-property-performance relationships are at the core of materials science research. Microstructure characterization provides the link to these four core areas, often through visualizing material microstructure using imaging techniques. However, linking microstructure image data (i.e., micrographs) to variables of interest (e.g., processing parameters, material chemistry) in a reproducible, generalizable, and quantitative manner is a significant challenge. Typically, quantitatively linking image data to processing history relies on significant domain knowledge and manual or subject matter expert (SME)-heuristic based image analysis. Such an approach to image analysis has the potential to be biased, inefficient, and difficult to replicate.

36 MATERIALS SCIENCE↗
DOE OSTI2018

The effect of boron addition on the deformation behavior and microstructure of β-solidify TiAl alloys

Highlights: • Borides could promote the DRX formation to soften TiAl alloys. • Boron addition increases firstly and then stabilizes the deformation activate energy. • The stable region expands with boron increasing in processing maps. • The DRX critical strain increases firstly and then decreases with boron increasing. • DRX softening and strengthening from solid solution and borides influence deformation behavior. - Abstract: The effect of boron addition on the deformation behavior and microstructure of Ti-43Al-6Nb-1Mo -1Cr alloys have been studied in this paper. Boron addition would induce Ti{sub 2}Al(P6{sub 3}/mmc) phase with hexagonal structure formation on the interfaces between TiB and γ phase. TiB would be the obstacles for dislocations slipping and increase the stacking fault energy. Ti{sub 2}Al could also provide the chemical foundation for DRXed γ nucleation and disappear after thermal deformation. Both these two phase could promote DRXed grains nucleation to soften the alloys during thermal deformation. With the strengthen effect of boron solid solution and TiB obstacles, the microstructure evolution, phase transformation and deformation behavior are also discussed and concluded as follow.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Effects of Cold Rolling on Microstructure and Mechanical Properties of Fe-30Mn-3Si-4Al-0.093C TWIP Steel

The effects of cold rolling on microstructure evolution and the associated mechanical properties of Fe-30Mn-3Si-4Al-0.093C twinning-induced plasticity (TWIP) steel are examined in this work with reduction rates of 10%, 20%, 30%, 40%, 50%, 60%, and 70%. Through texture analysis and transmission electron microscopy (TEM) observations, it is suggested that slip, mechanical twinning, the interaction between dislocation/twin boundaries (TB), and shear band have influenced the observed mechanical behavior and development of texture. Special components of weak initial textures are preferential for mechanical twinning, resulting in an increase in strain hardening rate. By mechanical twinning, the {111}<112> orientation is rotated into a position at the vicinity of the {110}<001> Goss orientation, and the {552}<115> (Cu-twin) texture is transformed to the {110}<001> orientation. The evolution of texture is closely related to the onset of shear banding resulting from deformation twinning. The sample with 10% cold reduction exhibits a favorable combination of yield strength and ductility, indicating a considerable capacity for energy absorption. With increasing rolling reductions, the deformation of the samples becomes inhomogeneous due to the high anisotropy of the microstructure. The localized shear bands resulting from the excessive cold rolling are detrimental to the ductility of the present TWIP steel.

Shen, Yongfeng↗
DOE OSTI2023

Annealing influence on the microstructure of irradiated U-Mo monolithic fuel foils

In this study we compared the microstructure evolution of U-Mo fuel foils produced with and without heat treatment at low burn-up via advanced post-irradiation examination. The aim of this study is to observe after irradiation the ways in which the fabrication processes have influenced fuel behavior at early-stage irradiation, as for very low burn up microstructural studies are lacking. In this work it was observed that the larger grain size detected in the heat-treated samples before irradiation led to decreased grain refinement after irradiation. Grain refinement was associated with the presence of small nano-size bubbles and precipitates. This phenomenon is hypothesized to influence early fuel swelling during reactor irradiation. Grain refinement was also observed to increase in regions where γ-U decomposition was present. Thus, it was enhanced in the samples fabricated without heat treatment. The heat treatment also increased the thickness of the U-Mo/Zr interface, namely of the UZr 2 layer. However, the influence of this layer on fuel performance needs further investigation. On one side, it may contribute to better mechanical bonding; on the other, it may influence swelling and blistering in the interaction layer as porosity increases when this layer is increased. This was observed especially in the presence of increased area containing low Mo concentration, and thus containing a higher fraction of the α-U phase, which is highly susceptible to irradiation induced swelling. Strong evidence of reverse transformation under irradiation (α-U + γ'-U2Mo → bcc γ-U) was observed in these samples. While the precipitates (carbides and oxide) seem to be unaffected by the irradiation at these low burnups. However, further analyses are necessary at higher burn-up to assess the exact impact different heat treatments have on fuel performance.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

Effects of in-process cryocooling on metallurgical and mechanical properties of friction stir processed Al7075 alloy

Highlights: • For in-process cryocooling (IPC) during FSP, an efficient cooling fixture was designed & fabricated. • FSP of Al7075 alloy with IPC setup suppressed precipitate coarsening as well as grain growth. • Nanosize η′ precipitates (20–30 nm) in IPC condition increased work hardening capacity & strength. • Simultaneous improvement in ductility & strength occurred for sample FSPed with IPC. - Abstract: Friction stir processing (FSP) of heat treatable aluminum alloys is reported to deteriorate strength and hardness properties in spite of huge grain size refinement. The improvement in strength due to the grain size refinement after FSP could not be able to offset the reduction in strength due to coarsening or dissolution of the strengthening precipitate(s). To overcome this, the present work investigates an effective way of heat rejection from the FSP zone to control the precipitate evolution besides the grain size refinement during FSP of Al7075 alloy. The FSP was carried out with standardized process parameters (i.e. 720 rpm, 65 mm/min traverse speed) under two different cooling environments: (i) at normal air cooling and (ii) by rushing a chilled mixture (−30 °C) of liquid nitrogen and methanol through the bottom of the backing plate. Microstructural evolution was examined through optical, scanning and transmission electron microscopy and electron backscatter diffraction to confirm the grain size and morphology of precipitate(s) formed. The in-process cryocooling during the FSP led to 65 and 72% improvement in the Vickers hardness and tensile strength, respectively, in comparison to the solutionized base metal. The results have been analyzed in terms of precipitate interface characteristics and its strengthening effect, Hall–Petch strengthening due to grain size reduction and tradeoff between them.

36 MATERIALS SCIENCE↗