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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 1,063 records · Page 59
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Annular Metallic Nuclear Fuel Informatics at 50 nm Resolution

U-10wt.% Zr (U-10Zr) based metallic fuel is the leading candidate for next-generation sodium cooled fast reactor in United States. Advanced post-irradiation characterization (from sub-nanometer to micrometer) helps to understand fuel microstructure and property change during irradiation, benefiting fuel qualification for commercial application. With high velocity image data generating method, an automatic way to extract the microstructural information quantitively can better serve the needs from post irradiation characterization. A trained machine learning model, named Decision Tree, is employed to categorize pores caused by fission gas release and to aid phase identification. This work presents a showcase of this approach on different irradiated U-10Zr metallic fuels. This quantitative data offers insights into the fission product migration and potentially thermal conductivity degradation. This information from machine learning will be fed into fuel design code for better prediction of fuel performance.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

A detailed study of the microstructure and thermal stability of typical SiC fibers

Highlights: • The cross-sectional microstructure and thermal stability of typical SiC fibers were characterized via SEM and TEM. • The SiC fiber with gradient microstructure has better properties than that with uniform microstructure. • The graphite exhibits straight planes on the fiber surface while they're turbostratic inside the fiber. Continuous SiC fibers have attracted increasing research interest for their significant application in aerospace and nuclear energy. Control of inhomogeneity and decrement of defects are crucial for improving the mechanical and high-temperature performance of SiC fibers. Thus an understanding of fine and detailed microstructural and microchemical distribution of SiC fibers is urgently needed. In the present work, the cross-sectional phase distributions, morphologies and defects of amorphous, non-stoichiometric and near-stoichiometric SiC fibers were well characterized. From surface to core, the amorphous and non-stoichiometric fibers exhibited uniform microstructures, but a gradient change along the radial direction was observed in the near-stoichiometric fiber. Nanosized SiC and turbostratic carbon (2–4 nm) were randomly distributed inside the amorphous fiber. A large amount of graphite surrounding SiC grains appears in the non-stoichiometric fiber which possess low strength and weak thermal stability. The near-stoichiometric fiber has transgranular fracturing, high strength and favorable thermal stability, and the graphite planes are turbostratic inside the fiber but straight on the surface. The results of both energy-dispersive X-ray spectrometry measurements and first-principles calculations demonstrate that Al atoms can occupy Si sites in the SiC grains. Our findings offer fine understanding for fabricating SiC fibers with superior properties.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2021

Model-informed, Adaptive Physical Vapor Deposition to Fabricate Hierarchical Binary-alloy Thin-films

Designing next generation thin films, tailor-made for specific applications, relies on the availability of robust processing-structure-property relationships. Traditional structure zone diagrams are limited to low-dimensional mappings, with machine-learning methods only recently attempting to relate multiple processing parameters to the final microstructure. Despite this progress, structure-processing relationships are unknown for processing conditions that vary during thin-film deposition, limiting the range of microstructures and properties achievable. In this project, we employed a phase-field computational model combined with a genetic algorithm (GA) to identify and design time-dependent processing protocols that achieve tailor-made microstructures. We simulate the physical vapor deposition of a binary-alloy thin film by employing a phase-field model, where deposition rates and diffusivities are controlled via the genetic algorithm. Our GA-guided protocols achieve targeted microstructures with lateral and vertical concentration modulations, as well as more complex, hierarchical microstructures previously not described in simple structure zone diagrams. Our algorithm provides insight to experimentalists looking for additional avenues to design novel thin-film microstructures.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Characterization of hot-pressed von Alpen type NASICON ceramic electrolytes

The Na-ion conducting solid electrolyte NASICON is a promising solid state electrolyte (SSE) for use in Na based electrochemical systems. The effects of particle morphology and synthesis of von Alpen type NASICON via hot-pressing were investigated. Spray dried particles were shown to improve mechanical and electrochemical properties. X-ray diffraction, scanning electron microscopy, impulse excitation measurements, Vickers hardness, and impedance spectroscopy were used to correlate relationships between phase purity, microstructure, mechanical properties, and electrochemical properties. Scanning electron microscopy showed the presence of a glass phase as between 19.08% and 28.23% area percentage and a ZrO 2 phase between 0.46% and 3.51% area percentage in the hot-pressed samples. Impulse excitation showed elastic modulus varying from 83.65 to 97.65 GPa. The first values of Poisson's ratio and shear modulus of NASICON are reported as between 0.23 and 0.26 and 33.87 to 38.79 GPa, respectively. Vickers hardness and fracture toughness measurements showed Vickers hardness ranging from 4.30 to 4.68 GPa and fracture toughness ranging from 1.05 to 1.09 MPa m ½ . Impedance spectroscopy showed grain conductivities ranging from 1.023 to 1.287 mS/cm, with grain boundary resistance percentages between 73.22 and 47.5%. Total conductivities ranged from 0.292 to 0.596 mS/cm, with 0.596 mS/cm being achieved at room temperature for the spray dried powders with lower grain boundary resistance percentages.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS2001

Structure-Property Correlations in Al-Li Alloy Integrally Stiffened Extrusions

The objective of this investigation was to establish the relationship between mechanical property anisotropy, microstructure and crystallographic texture in integrally 'T'-stiffened extruded panels fabricated from the Al-Li alloys 2195, 2098 and 2096. In-plane properties were measured as a function of orientation at two locations in the panels, namely mid-way between (Skin), and directly beneath (Base), the integral 'T' stiffeners. The 2195 extrusion exhibited the best combination of strength and toughness, but was the most anisotropic. The 2098 extrusion exhibited lower strength and comparable toughness, but was more isotropic than 2195. The 2096 extrusion exhibited the lowest strength and poor toughness, but was the most isotropic. All three alloys exhibited highly elongated grain structures and similar location-dependent variations in grain morphology. The textural characteristics comprised a beta + <100> fiber texture, similar to rolled product, in the Skin regions and alpha <111> + <100> fiber texture, comparable to axisymmetric extruded product, in the Base regions. In an attempt to quantitatively correlate texture with yield strength anisotropy, the original 'full constraint' Taylor model and a variant of the 'relaxed constraint' model, explored by Wert et al., were applied to the data. A comparison of the results revealed that the Wert model was consistently more accurate than the Taylor model.

Hales, Stephen J.↗
DOE OSTI2024

Microstructure, electrical resistivity, and tensile properties of neutron-irradiated Cu–Cr–Nb–Zr

High strength, high conductivity copper alloys that can resist creep at high temperatures are one of the primary candidates for efficient heat exchangers in fusion reactors. Cu–Cr–Nb–Zr (CCNZ) alloys, which were designed to improve the strength and creep life of ITER Cu–Cr–Zr (CCZ) reference alloys, have been found to have comparable electrical conductivity and tensile properties to CCZ alloys. The measured creep rupture times for these improved alloys is about ten times higher than the ITER reference alloys at 90–125 MPa at 500 °C. However, the effects of neutron irradiation on these alloys, and the ensuing material properties, have not been studied; thus, their utility in a fusion reactor environment is not well understood. This study characterizes the room temperature mechanical and electrical properties of a neutron-irradiated CCNZ alloy and compares them to a neutron-irradiated ITER reference heat sink CCZ alloy. Tensile specimens were neutron irradiated in the High Flux Isotope Reactor (HFIR) to 5 dpa between 250 °C and 325 °C. Post-irradiation characterization included electrical resistivity measurements, hardness, and tensile tests. Microstructural evaluation used scanning electron microscopy, energy dispersive x-ray spectroscopy, and atom probe tomography to characterize the irradiation-produced changes in the microstructure and investigate the mechanistic processes leading to post-irradiation properties. Transmutation calculations were validated with composition measurements from atom probe data and used to calculate contributions to the increased electrical resistivity measured after irradiation. Comparisons with CCZ alloys in the same irradiation heat found that the post-irradiated CCNZ and CCZ alloys had comparable electrical resistivity. Although CCNZ alloys suffered more irradiation hardening than CCZ, the overall tensile behavior deviated very little from non-irradiated values in the temperature range studied.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Influence of microstructure and temperature on impact toughness of H13 steel produced by binder jet additive manufacturing

Binder Jet Additive Manufacturing (BJAM) is a promising manufacturing pathway to produce H13 steel dies and tooling with complex geometries for applications in high pressure aluminum die casting, hot stamping, and injection molding. While fully dense H13 coupons produced using BJAM have been subjected to detailed microstructure characterization, properties which are critical and relevant to the aforementioned applications, such as impact toughness, have not been reported. Here, this work evaluated the influence of microstructural characteristics and test temperature on the impact toughness of H13 produced by BJAM. Coupons were produced from three different powder size distributions (PSDs), with nominal powder size ranges of −22 μm, 10-32 μm, and 15-53 μm. Coupons were printed, sintered, hot isostatically pressed (HIPed), and heat treated by quenching and tempering. After HIPing, the measured porosities of the different PSDs were all less than 0.015 vol%. The −22 μm PSD BJAM material exhibited the best impact toughness of all three PSDs across the entire test temperature range from 25 to 400 °C, and also exhibited an ambient temperature impact toughness of 10.9 J at a hardness of 46 HRC, equivalent to minimum threshold requirements for premium grade H13. However, all three BJAM PSDs exhibited moderately lower impact toughness than premium grade wrought H13 from RT to 400 °C. We attribute this in part due to the very large prior-austenite grain (PAG) sizes near 400 μm and segregation from former liquid channels leading to greater amounts of carbide precipitation on PAG boundaries. Technical pathways for optimizing processing and chemistry of BJAM H13 to further improve impact toughness are discussed.

Binder jet additive manufacturing↗
DOE OSTI2018

Influence of Boron on Austenite to Ferrite Transformation Behavior of Low Carbon Steel Under Continuous Cooling

In the current work, the influence of boron on austenite to ferrite transformation behavior under continuous cooling condition and its associated features, e.g., final microstructure, mechanical properties, etc., in low carbon steel has been studied. The steels (C 0.04 wt.%, B 10-100 ppm) prepared in an open air laboratory furnace showed identical microstructures having ferrite grains of 20-25 µm. However, tensile test data indicate variation of yield strength and ultimate tensile strength with boron content. The yield point elongation and strain aging index both were found to decrease with increase in boron content or boron-to-nitrogen ratio. As the boron nitride precipitates stimulate the nucleation of ferrite phase, the dilation curves show an increase in austenite to ferrite transformation start temperature with boron content. The resulting microstructure and hardness value also corroborate the finding. Transmission electron microscopy findings revealed the presence of ultra-fine boron nitride (BN) precipitates in both grain boundary and grain body of the steel having boron concentration of 30 ppm and beyond. The presence of these precipitates also increased with boron content. Based on austenite decomposition behavior, related microstructure and hardness values it is conjectured that these BN precipitates may act as nucleating agent for polygonal ferrite during austenite decomposition, thereby softening the steel during fast cooling.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Laser Powder Deposition Parametric Optimization and Property Development for Ti-6Al-4V Alloy

In this study, Ti6Al4V alloy was produced via laser powder deposition (LPD). To obtain Ti6Al4V alloy with maximum density, LPD parameters for preparing Ti6Al4V samples were optimized using the Taguchi method. Results were analyzed on the basis of the signal-to-noise (S/N) ratios and analyses of variance. A high energy density should be used to achieve higher levels of densification. The optimal combination of parameters for density was a scanning speed of 550 mm/min, laser power of 160 W, powder feeding rate of 0.99 g/min, and shield gas flow of 8 L/min. An almost fully dense Ti6Al4V sample was prepared using the optimized LPD process, and the relative density was greater than 99%. In addition, the microstructure and properties of Ti6Al4V samples prepared by optimized LPD process were investigated. The microstructure investigation revealed that the LPD-prepared Ti6Al4V sample was predominantly composed of fine acicular α phase and lath-type α phase. Tensile and microhardness tests indicated that the LPD sample had higher mechanical properties than the traditional cast Ti6Al4V alloy because of the acicular martensitic phase and smaller grain size.

36 MATERIALS SCIENCE↗
NASA NTRS1984

Deformation and fracture behavior of Ni-Mo-Al(gamma/gamma prime-alpha) in situ composite

Tensile properties of a directionally solidified (DS) eutectic alloy of the nominal composition Ni-33 Mo-5.7 Al (weight percent) have been investigated both at room temperature and elevated temperatures. The microstructure-mechanical property relationship has been studied for the alloy both in the as-DS and heat-treated conditions. Changes in the yield strength, the work hardening behavior, and the fracture morphology have been explained in terms of the microstructural changes due to the heat treatment. The yield drops observed have been attributed to the microdebonding due to the possible segregation of impurities at the fiber-matrix interface, and partly to the strain aging. The deformation mechanism has been identified to be the cutting of gamma prime particles.

Sriramamurthy, A. M.↗
DOE OSTI2017

Evaluation of Additively Manufactured Materials for Nuclear Plant Components

Powder bed fusion Direct Metal Laser Melting (DMLM) is an evolving additive manufacturing (AM) fabrication technology that is providing high performance parts to many industries. This technology has significant promise for use in building components for nuclear power plants. Implementation of materials produced using this and similar processes offer a potential step change in efficiency for complex parts production and hence a potential for innovative design as well as cost savings for components in the future. Properties of AM Type 316L have been reported in previous work, showing properties that match wrought properties. The fine grain structure may even lead to better environmental resistance. However, there is a need to confirm the behavior of these innovative materials after exposure to radiation if this innovative technology is to be used in current and future nuclear applications. This paper discusses new efforts being explored via a joint program between GE Hitachi (GEH) and INL (Idaho National laboratory) aimed at developing corresponding un-irradiated and irradiated data for AM materials. This paper will present data for both Type 316L stainless steel, a single-phase alloy, and Ni-base Alloy 718, a precipitation hardened alloy, manufactured using AM. This paper, serving as a progress report, will present the mechanical property and microstructural data for both Type 316L and 718 AM alloys to assess their correspondence to wrought alloy data and establish a baseline for future comparison to irradiated properties. The paper will end by discussing the requirements for using these and other additively manufactured materials in future reactor component applications where irradiated data is not available.

316 Stainless Steel↗
DOE OSTI2021

On the interactions between molten aluminum and high entropy alloy particles during aluminum matrix composite processing

The feasibility of adding AlCrTiV high entropy alloy (HEA) particles to molten aluminum to make metal matrix composites was studied. Equiatomic AlCrTiV HEA particles, produced by a solid state reduction process, were dispersed into pure aluminum and 7075 alloy (Al-5.8Zn-2.3Mg-1.4Cu, all weight %) melt and by a ultrasonic dispenser. It was found that the AlCrTiV particles reacted with molten aluminum, leading to the formation of Al 45 (Cr,V) 7 and Al 3 Ti intermetallic phases in the aluminum matrix composites. Although the AlCrTiV HEA particles did not survive in molten aluminum during composite processing, the final composite materials showed significantly improved mechanical properties, due to grain refinement and dispersion strengthening. Finally, the research suggests that the interactions between matrix aluminum alloys and the particles are key in controlling the final microstructure and properties of the composites.

36 MATERIALS SCIENCE↗
NASA NTRS1974

Microscopic investigation of cavitation erosion damage in metals

The results of research to identify the cavitation erosion damage mechanisms at the microscopic level for three metals (aluminum, stainless steel, and titanium) representing a range of properties and microstructure are presented. The metals were exposed to cavitation generated in distilled water by a 20-kHz ultrasonic facility operating at a vibration amplitude of 2 mils. Representative properties of the metals and experimental details are summarized. Replicas of the eroded surfaces of the specimens obtained periodically during exposure were examined with a transmission electron microscope to follow progression of the erosion damage and identify dominant erosion mechanisms as a function of exposure time. Eroded surfaces of selected specimens were also examined with a scanning electron microscope to assist in the interpretation.

Hackworh, J. V.↗
DOE OSTI2018

Evolution of the Fe{sup 3+} Ion Local Environment During the Phase Transition ε-Fe{sub 2}O{sub 3} → α-Fe{sub 2}O{sub 3}

Evolution of the local environment of Fe{sup 3+} ions in deposited Fe{sub 2}O{sub 3}/SiO{sub 2} nanoparticles formed in samples with different iron contents was investigated in order to establish the conditions for obtaining the stable ε-Fe{sub 2}O{sub 3}/SiO{sub 2} samples without impurities of other iron oxide polymorphs. Microstructure of the samples with an iron content of up to 16% is studied by high-resolution transmission electron microscopy, X-ray diffraction analysis, and Mössbauer spectroscopy, and their magnetic properties are examined. At iron concentrations below 6%, calcinations of iron-containing precursor nanoparticles in a silica gel matrix lead to the formation of the ε-Fe{sub 2}O{sub 3} iron oxide polymorphic modification without foreign phase impurities, while at the iron concentration in the range of 6–12%, the hematite phase forms in the sample in the fraction of no more than 5%. It is concluded on the basis of the data obtained that the spatial stabilization of iron-containing particles is one of the main factors facilitating the formation of the ε-Fe{sub 2}O{sub 3} phase in a silica gel matrix without other iron oxide polymorphs. It is demonstrated that the increase in the iron content leads to the formation of larger particles in the sample and gradual changes of the Fe{sup 3+} ion local environment during the phase transition ε-Fe{sub 2}O{sub 3} → α-Fe{sub 2}O{sub 3}.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2019

Effects of Nb on Superelasticity and Low Modulus Properties of Metastable β-Type Ti-Nb-Ta-Zr Biomedical Alloys

In this work, a series of Ti-xNb-2Ta-3Zr (x = 25, 30, 35, 40 wt.%) alloys are designed, and the transformation of β-phase to α″ martensitic, β-phase stability, microstructure, mechanical properties and corrosion performance of these alloys are investigated. The phase analysis shows as the Nb content increases, the α″ phase in these alloys decreases, while the intensity of the two main peaks β(110) and β(211) of Ti-40Nb-2Ta-3Zr alloy is reduced. These results can be attributed to the variation of β-phase stability caused by Nb element of alloy and cold rolling process. The mechanical properties test shows that the elastic modulus (52 GPa) of the Ti-35Nb-2Ta-3Zr alloy is the lowest and the elongation (18.8%) is the maximum. In addition, the alloy is susceptible to β-phase elastic deformation and stress-induced martensitic transformation resulting in the highest recovery strain of the alloy (66.87%). The polarization curves show that the Ti-35Nb-2Ta-3Zr alloy has the highest corrosion potential (− 0.34 V) and the lowest corrosion current density (0.21 μA cm{sup −2}) exhibiting the best corrosion resistance.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Bulk nanocrystalline Al–Mg–Y alloys with amorphous grain boundary complexions display high strength and compressive plasticity

Although nanocrystalline alloys regularly exhibit high strengths, their use in structural applications often face challenges due to sample size limitations, unstable microstructures, and the limited ability to plastically deform. The incorporation of amorphous grain boundary complexions has been proposed to address these issues, by simultaneously stabilizing nanocrystalline grain structures for scale-up processing and improving alloy toughness. In the present study, the mechanical behavior of bulk nanocrystalline Al–Mg–Y is examined with macroscale compression testing, probing a length scale that is relevant to real-world structural applications. Bulk samples were fabricated via a simple powder metallurgy approach, with different hot-pressing temperatures and durations employed for consolidation in order to investigate microstructural and property evolution. All of the specimens contained primary face-centered cubic Al and secondary Al 4 C 3 and Al 3 Y phases, with the Al 3 Y particles exhibiting two populations of small equiaxed and larger elongated particles. Appreciable plasticity was measured along with high ultimate stresses over 800 MPa due to the presence of amorphous grain boundary complexions. Microstructural characterization of fracture surfaces revealed that the area fraction of dimpled regions increased with longer hot-pressing time. Most importantly, the elongated Al 3 Y particles formed regular cellular patterns with increasing hot-pressing time, delaying shear localization and significantly enhancing plasticity. The hierarchy present in the microstructure of the Al–Mg–Y alloy, from amorphous grain boundary complexions to secondary phases, gives rise to excellent bulk mechanical properties, which are attractive for structural applications.

Bulk nanocrystalline alloy↗
DOE OSTI2019

Effect of Tempering Temperature on the Precipitation Behavior and Mechanical Properties of a Martensite Ferritic Steel

In this investigation, the precipitation of boron-containing M{sub 23}C{sub 6} in the CB2 steel during tempering was investigated. Scanning electron microscopy, energy-dispersive x-ray spectroscopy, transmission electron microscopy and differential scanning calorimetry were used to analyze the influence of temperature on the microstructure and properties of CB2-tempered martensite ferritic steel. The steel was normalized at 1100 °C for 2 h and then tempered at six different temperatures between 690 and 790 °C for 2 h. During air-cooling following austenitization, the precipitation of M{sub 3}C particles occurred in flakes forming with their diameter and thickness of 100 and 20 nm, respectively. The boron-containing M{sub 23}C{sub 6} was formed on the lath boundary after the dissolution of M{sub 3}C within the boundary. When the tempering temperature increased from 690 to 790 °C, the average diameter of boron-containing M{sub 23}C{sub 6} increased from 132 to 198 nm. Owing to the rapid growth of the precipitates, the phenomenon of lath widening as well as the recovery of microstructure would take place at high temperature. With an increase in the temperature, the tensile and yield strengths decreased gradually, while the plasticity increased and the boron-containing M{sub 23}C{sub 6} grew rapidly. Furthermore, when the tempering temperature exceeded 750 °C, the plasticity of CB2 steel was significantly improved.

36 MATERIALS SCIENCE↗
DOE OSTI2018

A review on the fatigue behavior of Ti-6Al-4V fabricated by electron beam melting additive manufacturing

Electron beam melting (EBM) is a swiftyly-developing metal additive manufacturing process that holds significant interest in the aerospace and biomedical industries for the high-strength titanium alloy, Ti-6Al-4V. These industries have fatigue-limited applications, yet a lack of understanding of the EBM process-microstructure-fatigue relationships limit widespread use and presents challenges for certification. In this review, uniaxial fatigue data was collected and the effects of build orientation, surface roughness, and hot-isostatic pressing are linked to the fatigue properties highlighting microstructure, defects, and failure mechanisms. The observations and conclusions are supported by statistical analysis using the mean fatigue life obtained by the Statistical Fatigue-Limit Model. Both EBM-process and post-process structure relationships are discussed in order to identify the best-practice for fatigue-resistant design. The performance of the EBM material is compared to conventionally manufactured Ti-6Al-4V and possible methods to increase the fatigue resistance are discussed. Anisotropic fatigue behavior was observed in as-fabricated parts and no statistical distinction was found in the fatigue performance of HIPed and as-fabricated material provided the same as-fabricated rough surface condition. However, comparable fatigue life to traditionally manufactured lamellar Ti-6Al-4V is achieved when both post-process HIP and machining are applied to EBM-fabricated parts.

36 MATERIALS SCIENCE↗