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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 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

High temperature thermal and mechanical stability of high-strength nanotwinned Al alloys

Al alloys have widespread applications, but often suffer from low yield strength. Recently, nanotwinned Al-Fe solid solution alloys have shown high flow stress (>1.5 GPa), ascribed to nanograins with abundant incoherent twin boundaries and solute-stabilized 9R phase. However, the high temperature mechanical behaviors of high-strength twinned Al-Fe alloys remain unknown. In this study, we show that nanotwinned microstructures are stable up to 280 °C, followed by recrystallization at 300 °C. In-situ uniaxial compression tests in a scanning electron microscope show that the nanotwinned Al alloys retain their high flow stress of ~1.3 GPa when tested up to 200 °C, and substantial softening occurs at a test temperature of 300 °C. This work reveals the superb thermal stability and high temperature mechanical behaviors of the nanotwinned Al-Fe alloys, and offers a new perspective to design future strong and thermally stable nanostructured Al alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Effects of Strain and Strain Rate on Dynamic Grain Growth and Subgrain Evolution During Plastic Deformation of an Interstitial-Free Steel at 850 ° C

Here, the effects of strain and strain rate on dynamic grain growth (DGG) and subgrain evolution are reported for an interstitial-free steel deformed at 850 ° C. Microstructures produced during tension tests at true-strain rates of 10 -4 and to 10 -3 s -1 true strains ranging from 0.02 to 0.2 were preserved following deformation. These were characterized using electron backscatter diffraction (EBSD), including the application of spherical harmonic transform indexing to produce high-angular-resolution EBSD (HR-EBSD) data. HR-EBSD data resolved the small misorientation angles of subgrain boundaries while imaging much larger data fields than possible with previously available techniques. The resulting data confirmed that steady-state flow stress is inversely proportional to the average subgrain size and that subgrain boundary misorientation angle increases with strain. The following new observations are reported. The rate of DGG increased with respect to time but decreased with respect to strain as strain rate increased. This behavior is rationalized through a simple model using separate rate parameters for the effects of time and strain. Subgrain size was not constant during steady-state deformation, but decreased slowly with increasing strain. Subgrain size distributions and subgrain boundary misorientation angle distributions were measured, and both remained approximately log-normal during steady-state deformation. Subgrain evolution demonstrated no dependence on parent grain size, crystallographic orientation, or Taylor factor. These new data suggest that steady-state flow stress is more likely controlled by the dislocation density internal to subgrains than by the spacing between subgrain boundaries.

dynamic grain growth↗
DOE OSTI2019

An investigation of geometrically necessary dislocations and back stress in large grained tantalum via EBSD and CPFEM

This study explores the evolution of GNDs and their effects on back stress through experimental and computational methods. Four large-grained tantalum tensile specimens were strained in uniaxial tension, electron backscatter diffraction (EBSD) data were collected, and geometrically necessary dislocation (GND) maps of the four specimens in the unloaded state were produced. EBSD-based GND maps revealed several types of features with high GND content which caused back stress in the specimens. Correlations between five geometrically-based grain boundary (GB) transmission factors and the GB GND content were evaluated, and statistically significant correlations were found for transmission factors based on Livingston and Chalmer’s N factor, Werner and Prantl’s slip transfer number, and GB misorientation. The sign of individual components of the Nye tensor were used to visually and quantitatively identify clustering of GNDs of the same sign, thus giving additional evidence of increasing back stress due to deformation. Deformation of one of the specimens was simulated using multiple CPFEM based modeling approaches and predicted stress-strain responses are compared. The super dislocation model (SD model) — a crystal plasticity finite element method (CPFEM) which incorporates elastic dislocation interactions — was able to isolate impact of back stress on the overall flow stress. The SD model predicted correct stresses when compared with experimental data; however, when the elastic interactions in the SD model were turned off, stress predictions were 25% too low. Thus, demonstrating the importance of incorporating back stress into the model.

42 ENGINEERING↗
NASA NTRS1978

Metamorphism, argon depletion, heat flow and stress on the Alpine fault

The Alpine fault of New Zealand is a major continental transform fault which was uplifted on its southeast side 4 to 11 km within the last 5 m.y. This uplift has exposed the Haast schists, which were metamorphosed from the adjacent Torlesse graywackes. The Haast schists increase in metamorphic grade from prehnite-pumpellyite facies 9-12 km from the fault through the chlorite and biotite zones of the greenschist facies to the garnet-oligoclase zone amphibolite facies within 4 km of the fault. These metamorphic zone boundaries are subparallel to the fault for 350 km along the strike. The K-Ar and Rb-Sr ages of the schists increase with distance from the fault: from 4 m.y. within 3 km of the fault to approximately 110 m.y. 20 km from the fault. Field relations show that the source of heat that produced the argon depletion aureole was the fault itself.

Scholz, C. H.↗
DOE OSTI2019

Characterization and Modeling of Hot Deformation Behavior of a Copper-Bearing High-Strength Low-Carbon Steel Microalloyed with Nb

This study investigates hot deformation behavior of a newly developed Cu-bearing high-strength low-carbon steel microalloyed with Nb (Nb-HSLC). A computational method based on experimental data was employed to design the chemical composition of the alloy. Compression tests were carried out in the temperature range of 850-1100 °C as well as strain rates of 0.001-10 s{sup −1} using BAHR Dil 805 A/D thermo-analyzer equipment. The Arrhenius-type constitutive equations were used to model the hot working behavior of the designed steel. Effects of friction and temperature rise during deformation were corrected to obtain the actual stresses. The results showed that the peak flow stress was increased with increasing Zener–Hollomon parameter. The obtained flow curves at strain rates lower than 0.1 s{sup −1} and temperatures above 950 °C represented the typical dynamic recrystallization (DRX) behavior, while the flow curves at temperatures lower than 950 °C at all strain rates were associated with continuous strain hardening. This feature is in good agreement with the precipitation temperature range of Nb(C, N) particles, i.e., 800-1000 °C. Moreover, the flow curves showed the serrations during hot deformation at strain rates of 0.001 and 0.01 s{sup −1}, indicating that the dynamic strain aging (DSA) phenomenon occurred at low strain rates. The best fit between “peak stress” and “deformation conditions” was obtained by a hyperbolic sine-type equation (R{sup 2} = 0.993). Therefore, the average activation energy was determined as 348 kJ mol{sup −1}. The agreement between the achieved model and experimental flow data was verified using the results of additional tests at a strain rate of 5 s{sup −1}. The maximum difference between the measured and predicted “peak stresses” was calculated as 5 Mpa.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Incorporating dynamic recrystallization into a crystal plasticity model for high-temperature deformation of Ti-6Al-4V

During hot deformation of (α + β) titanium alloys, the simultaneous action of strain and temperature in the (α + β) regime facilitates dynamic recovery, dynamic recrystallization (DRX), and phase transformations via non-equilibrium paths. DRX is manifested in the form of fine recrystallized α or β grains. Here, in the present study, a two-phase crystal plasticity finite element framework (CP-DRX) has been developed which incorporates DRX kinetics into the crystal plasticity (CP) model to predict the flow characteristics of Ti-6Al-4V alloys during thermo-mechanical processing. The CP slip system parameters, as well as elastic properties from both α and β phases of Ti, are calibrated for different strain rate conditions. An EBSD-informed two-phase microstructure representation has been utilized in the CP-DRX framework to explore the time-dependent evolution of DRX microstructure and crystal orientation for different strain rate conditions. The proposed CP-DRX can capture the evolution of crystal orientation and plastic flow stress–strain response of polycrystalline Ti-6Al-4V during the deformation process. Furthermore, the proposed model is able to capture the softening behavior, observed in average stress–strain response from experiments performed using a Gleeble thermomechanical simulator and predict the recrystallization texture.

(α+ β)-Titanium (Ti) Alloys↗
DOE OSTI2014

Atomic simulation of mechanical behavior of Mg in a super-lattice of nanocrystalline Mg and amorphous Mg-Al alloy

The mechanical properties of a super-lattice architecture composed of nanocrystalline Mg and Mg-Al amorphous alloy are investigated using molecular dynamics simulation. The results indicate that deformation mechanism of nanocrystalline Mg is obviously affected by the amorphous boundary spacing and temperature. The strength of the material increases with the decrease of amorphous boundary spacing, presenting a Hall-Petch effect at both 10 K and 300 K. A stress platform and following stiffness softening, as well as a linear strengthening in the plastic stage, are observed when the amorphous boundary spacing below 8.792 nm at 10 K. The implying reason may be that the amorphous boundary acts as the dislocations emission and absorption source. However, the second stress peak is not observed for the models at 300 K. Instead, the flow stress in plastic stage is a nearly constant value. The simulation demonstrates the emergence of the new grain, accompanied by the deformation twins and stacking faults associated with the plastic behaviors at 300 K. The general conclusions derived from this work may provide a guideline for the design of high-performance hexagonal close-packed metals.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
NASA NTRS2001

Viscoplastic Model Development to Account for Strength Differential: Application to Aged Inconel 718 at Elevated Temperature

The magnitude of yield and flow stresses in aged Inconel 718 are observed to be different in tension and compression. This phenomenon, called the Strength differential (SD), contradicts the metal plasticity axiom that the second deviatoric stress invariant alone is sufficient for representing yield and flow. Apparently, at least one of the other two stress invariants is also significant. A unified viscoplastic model was developed that is able to account for the SD effect in aged Inconel 718. Building this model involved both theory and experiments. First, a general threshold function was proposed that depends on all three stress invariants and then the flow and evolution laws were developed using a potential-based thermodynamic framework. Judiciously chosen shear and axial tests were conducted to characterize the material. Shear tests involved monotonic loading, relaxation, and creep tests with different loading rates and load levels. The axial tests were tension and compression tests that resulted in sufficiently large inelastic strains. All tests were performed at 650 C. The viscoplastic material parameters were determined by optimizing the fit to the shear tests, during which the first and the third stress invariants remained zero. The threshold surface parameters were then fit to the tension and compression test data. An experimental procedure was established to quantify the effect of each stress invariant on inelastic deformation. This requires conducting tests with nonproportional three-dimensional load paths. Validation of the model was done using biaxial tests on tubular specimens of aged Inconel 718 using proportional and nonproportional axial-torsion loading. These biaxial tests also helped to determine the most appropriate form of the threshold function; that is, how to combine the stress invariants. Of the set of trial threshold functions, the ones that incorporated the third stress invariant give the best predictions. However, inclusion of the first stress invariant does not significantly improve the model predictions. The model shows excellent predictive capability for nonproportional load paths. Additionally, it reduces to the well-known models of Mises Drucker and Drucker-Prager. The requisite experiments involve reasonably simple load paths in the axial-shear stress plane and hence can be performed on a variety of different materials: be they metallic, geological. polymeric, ceramic or granular. The general form of the threshold function allows representation of inelastic deformation in a range of materials.

Iyer, Saiganesh↗
DOE OSTI2018

Mechanical behavior and texture development of over-aged and solution treated Al-Cu-Mg alloy during multi-directional forging

The effects of initial heat treatments, i.e. solution treating and over ageing, on deformation behavior of an age hardenable Al-Cu-Mg alloy, including mechanical properties and texture evolution, during multi-directional forging (MDF) are investigated. Hardness measurements, electron back scatter diffraction (EBSD) maps, and differential scanning calorimetry (DSC) are carried out. Mechanical behaviors of the alloy in terms of compressive stress and hardness test after MDF are investigated. In both solution treated and over-aged alloys, the compressive stress during MDF shows an increase up to the second pass, and by further straining the flow stress is decreased. However, shear and deformation bands are formed in both solution treated and over-aged alloys, the density of these instabilities in the solution treated alloy is higher than that in over-aged alloy. In the solution treated alloy, not only large particles induce deformation bands, but also the dynamically formed GPB zones/Cu-Mg co-clusters. Texture analysis shows that the shear component of C {001}<110> (Φ{sub 1} = 90°, Φ = 0°, Φ{sub 2} = 45°) is developed with 18 mrd during MDF of the over-aged alloy. In the solution treated alloy, due to the high density of deformation bands and different microchemistry of the matrix in comparison with that of the over-aged alloy, the Copper type texture component {112}<111> (Φ{sub 1} = 90°, Φ = 35°, Φ{sub 2} = 45°) is developed with 11 mrd.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Deformation Behavior of a Coarse-Grained Mg-8Al-1.5Ca-0.2Sr Magnesium Alloy at Elevated Temperatures

The compression tests were carried out on a coarse-grained Mg-8Al-1.5Ca-0.2Sr magnesium alloy samples at temperatures from 300 to 450 °C and strain rates from 0.001 to 10 s{sup −1}. The flow stress curves were analyzed using the double-differentiation method, and double minima were detected on the flow curves. The first set of minima is shown to identify the critical strain for twinning, while the second set indicates the critical strain for the initiation of dynamic recrystallization (DRX). Twin variant selection was numerically identified by comprehensive analysis of the Schmid factors for different deformation modes and the accommodation strains imposed on neighboring grains. It was found that twinning is initiated before DRX. Dynamic recrystallization volume increases with strain rate at a given deformation temperature. At high strain rate, various twin variants are activated to accommodate deformation, leading to the formation of twin intersections and high DRX volume. Fully dynamic recrystallized structure can be obtained at both high and low strain rates due to the high mobility of the grain and twin boundaries at the temperature of 400 °C.

36 MATERIALS SCIENCE↗
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 OSTI2019

Hardening of A6111-T4 Aluminum Alloy at Large Strains and Its Effect on Sheet Forming Operations

In a number of sheet metal stamping and joining processes, the material undergoes large plastic deformation exceeding the range of plastic strain achievable in a standard tensile test prior to material plastic instability. In order to extend the range of effective strains, the multistep rolling process was employed which enabled prestraining of aluminum sheet above 2.0 of true strain. Tensile testing of rolled samples was used to identify the flow stress corresponding to the level of prestrain: By varying the prestrain level, several data points were obtained for the studied flow curve. The numerical simulation using Abaqus software for the cold rolling process of aluminum strips confirmed that majority of the strip is deformed in plane strain compression condition. Performed simulation of the LDH test determined that earlier fracture might occur if the curve obtained via rolling–tensile testing approach is used versus traditional power law approximation and Voce law approximation. The results of simulation for the multistep drawing of a cylindrical cup revealed possible wrinkling in the die entry area during redrawing stage of the process if the rolling–tensile testing flow curve is employed.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Hot Deformation and Processing Maps of B{sub 4}C/6061Al Nanocomposites Fabricated by Spark Plasma Sintering

We developed 3 vol.% B{sub 4}C/6061Al nanocomposites by spark plasma sintering. We then characterized their flow and hot deformation behaviors using isothermal compression tests at deformation temperatures of 673-823 K and strain rates of 0.001-1 s{sup −1}. Results indicated that their steady flow characteristic can be described by the Zener–Hollomon parameter (Z) as a hyperbolic-sine function of flow stress. Based on pinning effect from B{sub 4}C nanoparticles, the estimated activation energy was calculated to be 274.80 kJ/mol. At the unstable deformation condition (723 K/1 s{sup −1}) with high Z, flow localization appeared; the main softening mechanisms involved are dynamic recovery and dynamic recrystallization (DRX). At the stable deformation condition (823 K/0.001 s{sup −1}) with low Z, adequate DRX occurred. Based on the processing map and microstructure evolution, the optimum hot working conditions for B{sub 4}C/6061Al nanocomposites were determined to be a deformation temperature of 773-823 K and a strain rate of 0.001-0.003 s{sup −1}. These working conditions were verified by a hot extrusion test.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Powder metallurgy processing and deformation characteristics of bulk multimodal nickel

Spark plasma sintering was used to process bulk nickel samples from a blend of three powder types. The resulting multimodal microstructure was made of coarse (average size ∼ 135 μm) spherical microcrystalline entities (the core) surrounded by a fine-grained matrix (average grain size ∼ 1.5 μm) or a thick rim (the shell) distinguishable from the matrix. Tensile tests revealed yield strength of ∼ 470 MPa that was accompanied by limited ductility (∼ 2.8% plastic strain). Microstructure observation after testing showed debonding at interfaces between the matrix and the coarse entities, but in many instances, shallow dimples within the rim were observed indicating local ductile events in the shell. Dislocation emission and annihilation at grain boundaries and twinning at crack tip were the main deformation mechanisms taking place within the fine-grained matrix as revealed by in-situ transmission electron microscopy. Estimation of the stress from loop's curvature and dislocation pile-up indicates that dislocation emission from grain boundaries and grain boundary overcoming largely contributes to the flow stress. - Highlights: • Bulk multi-modal Ni was processed by SPS from a powder blend. • Ultrafine-grained matrix or rim observed around spherical microcrystalline entities • Yield strength (470 MPa) and ductility (2.8% plastic strain) were measured. • Debonding was found at the matrix/microcrystalline entity interfaces. • In-situ TEM showed twinning, dislocation emission and annihilation at grain boundaries.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Constitutive Modeling of the Hot Deformation Behavior in 6082 Aluminum Alloy

The hot compressive tests of 6082 aluminum alloy were conducted on a Gleeble-3500 thermomechanical simulator at temperature ranges of 380-530 °C and strain rate range of 0.01-10 s{sup −1}. The constitutive analysis and microstructural evolution of the alloy were investigated. It was indicated that the peak stress increased with increasing strain rate and decreasing temperature. Dynamic recovery and dynamic recrystallization lead to the softening behavior of the alloy. In order to characterize the flow behavior of this alloy, some models were established based on the experimental data including the phenomenological Arrhenius-type model, the physically based Estrin and Mecking (EM) model for work hardening and dynamic recovery, and the EM model, which was combined with the Avrami equation for dynamic recrystallization. An artificial neural network model was also established to predict the flow stress. The results indicate that the Arrhenius-type model is more simple and more efficient than the EM + Avrami model. Moreover, the well-trained ANN model has the best predicting performance.

36 MATERIALS SCIENCE↗