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At least 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
DOE OSTI2017

Multi Resolution In-Situ Testing and Multiscale Simulation for Creep Fatigue Damage Analysis of Alloy 617

This report outlines the research activities that were carried out for the integrated experimental and simulation investigation of creep-fatigue damage mechanism and life prediction of Nickel-based alloy, Inconel 617 at high temperatures (950° and 850°). First, a novel experimental design using a hybrid control technique is proposed. The newly developed experimental technique can generate different combinations of creep and fatigue damage by changing the experimental design parameters. Next, detailed imaging analysis and statistical data analysis are performed to quantify the failure mechanisms of the creep fatigue of alloy 617 at high temperatures. It is observed that the creep damage is directly associated with the internal voids at the grain boundaries and the fatigue damage is directly related to the surface cracking. It is also observed that the classical time fraction approach does not has a good correlation with the experimental observed damage features. An effective time fraction parameter is seen to have an excellent correlation with the material microstructural damage. Thus, a new empirical damage interaction diagram is proposed based on the experimental observations. Following this, a macro level viscoplastic model coupled with damage is developed to simulate the stress/strain response under creep fatigue loadings. A damage rate function based on the hysteresis energy and creep energy is proposed to capture the softening behavior of the material and a good correlation with life prediction and material hysteresis behavior is observed. The simulation work is extended to include the microstructural heterogeneity. A crystal plasticity finite element model considering isothermal and large deformation conditions at the microstructural scale has been developed for fatigue, creep-fatigue as well as creep deformation and rupture at high temperature. The model considers collective dislocation glide and climb of the grains and progressive damage accumulation of the grain boundaries. The glide model incorporates a slip resistance evolution model that characterizes the solute-drag creep effects and can capture well the stress-strain and stress time response of fatigue and creep-fatigue tests at various strain ranges and hold times. In order to accurately capture the creep strains that accumulate particularly at relatively low stress levels, a dislocation climb model has been incorporated into the crystal plasticity modeling framework. The dislocation climb model parameters are calibrated and verified through experimental creep tests performed at 950°. In addition, a cohesive zone model has been fully implemented in the context of the crystal plasticity finite element model to capture the intergranular creep damage. The parameters of the cohesive zone model have been calibrated using available experimental data. The numerical simulations illustrate the capability of the proposed model in capturing damage initiation and growth under creep loads as compared to the experimental observations. The microscale analysis sheds light on the crack initiation sites and propagation patterns within the microstructure. The model is also utilized to investigate the hybrid-controlled creep-fatigue tests and has been found to capture reasonably well the stress-strain response with different hold times and hold stress magnitudes.

36 MATERIALS SCIENCE↗
DOE OSTI2015

The inhibiting effect of dislocation helices on the stress-induced orientation of S' precipitates in Al–Cu–Mg alloy

The phenomenon of restrained stress-induced preferential orientation of S′ precipitates is investigated using a single-crystal of Al–1.23Cu–0.43 Mg alloy. Al–1.23Cu–0.43 Mg single-crystal specimens are subjected to stress aging, and the microstructure is analyzed by transmission electron microscopy (TEM). It is found that the stress-induced preferential orientation of S′ precipitates is restrained owing to the dislocations produced by a higher stress. The effect of dislocations on the oriented precipitates depends on the total length of the intersection lines for precipitate habit planes and dislocation glide planes. This investigation not only provides important insight into solving the anisotropy problem attributed to precipitation strengthening, but also offers a benchmark for choosing the appropriate stress range in manufacturing of Al–Cu–Mg alloys. - Highlights: • Single crystals of an Al–Cu–Mg alloy were prepared for the investigations. • A phenomenon of restrained stress-induced preferential orientation of S′ precipitates was found. • The influence of dislocation helices on precipitation during stress-aging was studied. • Difference of orientation degree of S′ precipitates and θ′ precipitates was explained. • A basis for choosing the appropriate stress range in manufacturing of Al–Cu–Mg alloys is provided.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Scale transition using dislocation dynamics and the nudged elastic band method

Microstructural features such as precipitates or irradiation-induced defects impede dislocation motion and directly influence macroscopic mechanical properties such as yield point and ductility. In dislocation-defect interactions both atomic scale and long range elastic interactions are involved. Thermally assisted dislocation bypass of obstacles occurs when thermal fluctuations and driving stresses contribute sufficient energy to overcome the energy barrier. The Nudged Elastic Band (NEB) method is typically used in the context of atomistic simulations to quantify the activation barriers for a given reaction. In this work, the NEB method is generalized to coarse-grain continuum representations of evolving microstructure states beyond the discrete particle descriptions of first principles and atomistics. The method we employed enables the calculation of activation energies for a View the MathML source glide dislocation bypassing a [001] self-interstitial atom loop of size in the range of 4-10 nm with a spacing larger than 150nm in α-iron for a range of applied stresses and interaction geometries. This study is complemented by a comparison between atomistic and continuum based prediction of barriers.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Evaluation of microstructure anisotropy on room and medium temperature ECAP deformed F138 steel

The microstructure developed during severe plastic deformation results in improved mechanical properties because of the decrease in domain sizes and accumulation of defects, mainly dislocation arrays. The characteristic deformation stages observed in low stacking fault energy (SFE) face centered cubic (FCC) materials are highly influenced by the development of the primary and secondary twinning that compete with dislocation glide. In this paper, a low SFE F138 stainless steel is deformed by equal channel angular pressing (ECAP) up to 4 passes at room temperature (RT) and at 300 °C to compare the grain refinement and twin boundary development with increasing deformation. Tensile tests were performed to determine the deformation stages reached by the material before and after ECAP deformation, and the resulting microstructure was observed by TEM. X-ray diffraction and EBSD, average technique the first and local the second one, were used to quantify the microstructural changes, allowing the determination of diffraction domain sizes, dislocation and stacking fault densities and misorientation indices, which lead to a complete analysis of the deformation introduced in the material, with comparative correlations between various microstructural parameters. - Highlights: • The microstructure of ECAP pressed F138 steel was studied using TEM, EBSD and XRD. • Increasing deformation reduced domain sizes and increased dislocation densities. • Dislocation array compactness and misorientation increased with higher deformation. • Largest dislocation densities, mostly screw, match with simultaneous activation of twins. • Several correlations among microstructural features and parameters have been disclosed.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Phase stability and tensile behavior of metastable β Ti-V-Fe and Ti-V-Fe-Al alloys

Highlights: • A series of metastable β Ti-V-Fe and Ti-V-Fe-Al alloys were designed by molybdenum equivalency. • Ti-16V-Fe alloy deforms via {332}<113> twinning and stress-induced ω phase transformation. • Ti-12V-2Fe-Al and Ti-14V-2Fe-Al alloys deform via {332}<113> twinning and stress-induced α″ phase transformation. • Al addition suppresses athermal ω phase transformation in β Ti-V-Fe-Al alloys. • Fe and Al additions produce an effective solid-solution hardening for β Ti-(12-14)V-2Fe-Al alloys deformed via twinning. - Abstract: The tensile property and deformation microstructure of a series of metastable β Ti-V-Fe and Ti-V-Fe-Al alloys have been studied. The results show that although Al is an α-stabilizer element, Al addition suppresses the athermal ω phase transformation in metastable β Ti-V-Fe-Al alloys. The Ti-16V-Fe alloy plastically deforms via {332}<113> mechanical twinning and stress-induced ω phase with a special habit plane of {−5052}{sub ω}//{3-3-2}{sub β}, and the Ti-14V-2Fe-Al and Ti-12V-2Fe-Al alloys via {332}<113> twinning. The Ti-16V-2Fe, Ti-16V-2Fe-Al and Ti-16V-2Fe-2Al alloys with relatively high β phase stability plastically deforms mainly via dislocation glide. The Ti-16V-Fe, Ti-14V-2Fe-Al and Ti-12V-2Fe-Al alloys exhibit higher yield strength without loss of plasticity significantly than the binary β Ti-V alloys deformed via {332}<113> twinning due to solid-solution strengthening effect of Fe and Al elements in the alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Chapter 21. Atomic-Level Dislocation Dynamics in Irradiated Metals

Primary damage and microstructure evolution in structural nuclear materials operating under conditions of a high flux of energetic atomic particles and high temperature and stress lead to the formation of a high concentration, non-homogeneous distribution of defect clusters in the form of dislocation loops, voids, gas-filled bubbles and radiation-induced precipitates of nanometer scale. They cause changes in many material properties. Being obstacles to dislocation glide, they strongly affect the mechanical properties, with an increase in yield and flow stresses and a reduction in ductility. Atomic-scale computer simulations can provide details of how these effects are influenced by the obstacle structure, applied stress, strain rate and temperature. Processes such as obstacle cutting, transformation, absorption and drag are observed. Some recent results for body-centered and face-centered cubic metals are described in this review and, where appropriate, comparisons are drawn with predictions based on the elasticity theory of crystal defects. Perspectives on how to use this information at higher scales and in particular in mesoscale, dislocation dynamics simulations are also discussed.

Osetskiy, Yury N.↗
DOE OSTI2013

Fundamental Understanding of Ambient and High-Temperature Plasticity Phenomena in Structural Materials in Advanced Reactors

The goal of this research project is to develop the methods and tools necessary to link unit processes analyzed using atomistic simulations involving interaction of vacancies and interstitials with dislocations, as well as dislocation mediation at sessile junctions and interfaces as affected by radiation, with cooperative influence on higher-length scale behavior of polycrystals. These tools and methods are necessary to design and enhance radiation-induced damage-tolerant alloys. The project will achieve this goal by applying atomistic simulations to characterize unit processes of: 1. Dislocation nucleation, absorption, and desorption at interfaces 2. Vacancy production, radiation-induced segregation of substitutional Cr at defect clusters (point defect sinks) in BCC Fe-Cr ferritic/martensitic steels 3. Investigation of interaction of interstitials and vacancies with impurities (V, Nb, Ta, Mo, W, Al, Si, P, S) 4. Time evolution of swelling (cluster growth) phenomena of irradiated materials 5. Energetics and kinetics of dislocation bypass of defects formed by interstitial clustering and formation of prismatic loops, informing statistical models of continuum character with regard to processes of dislocation glide, vacancy agglomeration and swelling, climb and cross slip This project will consider the Fe, Fe-C, and Fe-Cr ferritic/martensitic material system, accounting for magnetism by choosing appropriate interatomic potentials and validating with first principles calculations. For these alloys, the rate of swelling and creep enhancement is considerably lower than that of face-centered cubic (FCC) alloys and of austenitic Fe-Cr-Mo alloys. The team will confirm mechanisms, validate simulations at various time and length scales, and improve the veracity of computational models. The proposed research's feasibility is supported by recent modeling of radiation effects in metals and alloys, interfacial dislocation transfer reactions in nano-twinned copper, and dislocation reactions at general boundaries, along with extensive modeling cooperative effects of dislocation interactions and migration in crystals and polycrystals using continuum models.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2018

Two Stages of Impact Fracture of Polycrystalline ZnS and ZnSe Compounds

Mechanoluminescence (ML) in ductile solids is caused by the motion of charged dislocations in the deformable material. Interatomic bond ruptures followed by electronic structure reconfiguration are the main source of ML in brittle bodies. We studied ML in ceramics composed of mixed ionic/covalent ZnS and ZnSe compounds, which are generated during impact loading higher than the limit deformation. Depending on synthesis method and thermal treatment, the resulting ceramics had different size and geometry of grains and intergrain boundary structure, which presumably may have a significant effect on the dislocation glide. In both materials, the time sweeps of ML pulses have two well-resolved peaks. The position of the peaks along the time axis is substantially dependent on the size of ceramic-forming grains and, to a smaller extent, on the barrier properties of intergrain boundaries. The first peak is associated with plastic deformation preceding disintegration of the crystal structure. The second peak emerges upon crack nucleation as interatomic bonds are ruptured and the material is undergoing local deformation in tips of propagating cracks. The distributions of ML pulse amplitudes (the dependences between the number of pulses and their amplitude) calculated for both peaks individually follow the power law, which demonstrates that the electronic processes having different excitation mechanisms (dislocation motion vs bond rupture) are correlated.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2015

Atomic-level level dislocation dynamics in irradiated metals

Primary damage and microstructure evolution in structural nuclear materials operating under conditions of a high flux of energetic atomic particles and high temperature and stress lead to formation of a high concentration, non-homogeneous distribution of defect clusters in the form of dislocation loops, voids, gas-filled bubbles and radiation-induced precipitates of nanometer scale. They cause changes in many material properties. Being obstacles to dislocation glide, they strongly affect mechanical properties in particular. This gives rise to an increase in yield and flow stress and a reduction in ductility. Atomic-scale computer simulation can provide details of how these effects are influenced by obstacle structure, applied stress, strain rate and temperature. Processes such as obstacle cutting, transformation, absorption and drag are observed. Some recent results for body-centered and face-centered cubic metals are described in this review and, where appropriate, comparisons drawn with predictions based on elasticity theory of crystal defects.

dislocations↗
DOE OSTI2015

Epitaxial growth of tungsten layers on MgO(001)

Smooth single crystal W(001) layers were grown on MgO(001) substrates by magnetron sputtering at 900 °C. X-ray diffraction ω–2θ scans, ω-rocking curves, pole figures, and reciprocal space maps indicate a 45°-rotated epitaxial relationship: (001){sub W}‖(001){sub MgO} and [010]{sub W}‖[110]{sub MgO}, and a relaxed lattice constant of 3.167 ± 0.001 nm. A residual in-plane biaxial compressive strain is primarily attributed to differential thermal contraction after growth and decreases from −0.012 ± 0.001 to −0.001 ± 0.001 with increasing layer thickness d = 4.8–390 nm, suggesting relaxation during cooling by misfit dislocation growth through threading dislocation glide. The in-plane x-ray coherence length increases from 3.4 to 33.6 nm for d = 4.8–390 nm, while the out-of-plane x-ray coherence length is identical to the layer thickness for d ≤ 20 nm, but is smaller than d for d ≥ 49.7 nm, indicating local strain variations along the film growth direction. X-ray reflectivity analyses indicate that the root-mean-square surface roughness increases from 0.50 ± 0.05 to 0.95 ± 0.05 nm for d = 4.8–19.9 nm, suggesting a roughness exponent of 0.38, but remains relatively constant for d > 20 nm with a roughness of 1.00 ± 0.05 nm at d = 47.9 nm.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Accelerated creep profiling: a high-throughput thermal- and stress-gradient approach applied to additive and wrought stainless steel

Here, this study investigates logarithmic creep behavior at temperatures near room temperature in wrought and additively manufactured (AM) 316 L austenitic stainless steel. A novel high-throughput (HiTp) methodology employed thermal gradients to obtain stress- and temperature-dependence of creep behavior. The findings, based on 104 two-week creep tests, reveal significant differences in creep response between wrought and AM materials. Compared to the wrought material, the AM material exhibited a higher activation energy and a lower activation volume. These differences were attributed to the materials’ distinct microstructural features, e.g., dislocation cell structures and precipitate distributions, which alter the susceptibility to dislocation glide creep, particularly at stresses below the yield stress. The HiTp methodology provides both an accelerated determination of low-temperature creep mechanisms, offering critical data for the design and optimization of alloys in near-ambient, high stress applications.

316 L Stainless steel↗
DOE OSTI2013

3D microband boundary alignments and transitions in a cold rolled commercial purity aluminum alloy

In the study of microband formation during plastic deformation of face centered cubic metals and alloys, two theories have been proposed regarding the orientations of their boundaries: (i) they are aligned parallel to crystallographic planes associated with dislocation glide (i.e. (111) planes in FCC metals), or (ii) they are aligned in accordance with the macroscopic stress state generated during deformation. In this study, high resolution 3D electron backscatter diffraction (3D EBSD) was used to investigate the morphology and crystallographic nature of microband boundaries within a 19 × 9 × 8.6 μm volume of a deformed grain in commercial purity aluminum cold rolled to 22% reduction. It was found that microband boundaries correspond to both theories of orientation. Additionally, a single surface may contain both crystallographic and non-crystallographic alignments. Misorientations across boundaries in the regions of microband triple junctions have been identified for both boundary alignments. - Highlights: ► Reconstruction of a 3D volume of crystallographic orientations from EBSD data ► Subgrain features accurately reconstructed using specially designed strategies. ► Microband boundaries contain crystallographic and non-crystallographic alignments. ► Boundaries form by crystallographic process but rotate to non-crystallographic.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Creep study of mechanisms involved in low-temperature superplasticity of UFG Ti-6Al-4V processed by SPD

The deformation kinetics of ultrafine-grained Ti-6Al-4V with mean (sub)grain size about 150 nm (produced by isothermal multiaxial forging) and superplastic properties at the relatively low temperature of 873 K was investigated in compression and tension over a large range of strain rates from 10{sup −7} to 10{sup −2} s{sup −1}. Electron microscopic observations showed that the grains coarsen during deformation towards the quasi-stationary spacing w{sub qs} of strain induced boundaries. In spite of the grain coarsening the grains were generally smaller than w{sub qs} allowing high-angle boundaries to dominate the quasi-stationary strength. Texture measurements indicate that dislocation glide plays a large role in deformation. Glide in this alloy is significantly influenced by solid solution strengthening leading to a stress sensitivity of strain rate of n = 3. The present ultrafine-grained Ti alloy displays a stress sensitivity exponent n = 2 over an extended stress range where its superplastic behavior is optimal. While the deformation kinetics of present ultrafine-grained Ti alloy can be roughly explained by the traditional formula for superplastic flow, the significant discrepancy to the measured values suggests that solid solution strengthening must be taken into account to get a complete insight. - Highlights: • The UFG Ti-6Al-4V alloy behaves superplastically at low temperature of 873 K. • Grain coarsening at low stresses limits superplasticity of UFG Ti alloy. • Solute strengthening plays an important role in low-temperature superplasticity. • Acceleration of creep in UFG Ti alloy is caused by processes related to hab.

36 MATERIALS SCIENCE↗
DOE OSTI2013

2nd World Congress on Integrated Computational Materials Engineering, Part II: Process Optimization: Multi-Objective Optimization of Microstructure in Wrought Magnesium Alloys.

The microstructural features that govern the mechanical properties of wrought magnesium alloys include grain size, crystallographic texture, and twinning. Several processes based on shear deformation have been developed that promote grain refinement, weakening of the basal texture, as well as the shift of the peak intensity away from the center of the basal pole figure — features that promote room temperature ductility in Mg alloys. At ORNL, we are currently exploring the concept of introducing nano-twins within sub-micron grains as a possible mechanism for simultaneously improving strength and ductility by exploiting a potential dislocation glide along the twin-matrix interface — a mechanism that was originally proposed for face-centered cubic materials. Specifically, we have developed an integrated modeling and optimization framework in order to identify the combinations of grain size, texture and twin spacing that can maximize strength-ductility combinations. A micromechanical model that relates microstructure to material strength is coupled with a failure model that relates ductility to a critical shear strain and a critical hydrostatic stress. The micro-mechanical model is combined with an optimization tool based on genetic algorithm. A multi-objective optimization technique is used to explore the strength-ductility space in a systematic fashion and identify optimum combinations of the microstructural parameters that will simultaneously maximize the strength-ductility in the alloy.

crystal plasticity↗
DOE OSTI2018

An Fe-Ni-Cr embedded atom method potential for austenitic and ferritic systems: An Fe-Ni-Cr embedded atom method potential for austenitic and ferritic systems

Fe-Ni-Cr stainless-steels are important structural materials because of their superior strength and corrosion resistance. Atomistic studies of mechanical properties of stainless-steels, however, have been limited by the lack of high-fidelity interatomic potentials. Here in this paper, using density functional theory as a guide, we have developed a new Fe-Ni-Cr embedded atom method potential. We demonstrate that our potential enables stable molecular dynamics simulations of stainless-steel alloys at high temperatures, accurately reproduces the stacking fault energy—known to strongly influence the mode of plastic deformation (e.g., twinning vs. dislocation glide vs. cross-slip)—of these alloys over a range of compositions, and gives reasonable elastic constants, energies, and volumes for various compositions. The latter are pertinent for determining short-range order and solute strengthening effects. Our results suggest that our potential is suitable for studying mechanical properties of austenitic and ferritic stainless-steels which have vast implementation in the scientific and industrial communities.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Prediction of Precipitation Strengthening in the Commercial Mg Alloy AZ91 Using Dislocation Dynamics

In this paper, dislocation dynamics simulations were used to predict the strengthening of a commercial magnesium alloy, AZ91, due to β-Mg 17 Al 12 formed in the continuous precipitation mode. The precipitate distributions used in simulations were determined based on experimental characterization of the sizes, shapes, and number densities of the precipitates for 10-hour aging and 50-hour aging. For dislocations gliding on the basal plane, which is expected to be the dominant contributor to plastic deformation at room temperature, the critical resolved shear stress to bypass the precipitate distribution was 3.5 MPa for the 10-hour aged sample and 16.0 MPa for the 50-hour aged sample. The simulation results were compared to an analytical model of strengthening in this alloy, and the analytical model was found to predict critical resolved shear stresses that were approximately 30 pct lower. A model for the total yield strength was developed and compared with experiment for the 50-hour aged sample. Finally, the predicted yield strength, which included the precipitate strengthening contribution from the DD simulations, was 132.0 MPa, in good agreement with the measured yield strength of 141 MPa.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Modeling the Work Hardening Behavior of High-Manganese Steels

The work hardening of a series of high-manganese steels with various chemical compositions (manganese contents of 18–30 wt.% and carbon contents of 0.06–1.2 wt.%) and deformation products (mechanical twins and/or ε-martensite) was modeled using a physics-based model. The model comprised the contributions of dislocation glide and phase transition (mechanical twinning and/or ε-martensite formation) kinetics to the overall work hardening rate. The model parameters included the physical characteristics of the steels such as the stacking fault energy as well as the microstructural features such as the volume fraction of the deformation products. A key point of the model was that it is globally applicable for all high-manganese steels—including twinning-induced plasticity and/or transformation-induced plasticity steels—instead of being limited to a specific category of these steels. A good agreement was found between the predicted and observed work hardening for all the experimental alloys in this study as well as several high-manganese steels in the literature.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Microstructural and Property Evolution of Continuous Columnar-Grained Polycrystalline Copper during Extreme Plastic Deformation at Room Temperature

An extreme extensibility with a true strain of 11.12 has been obtained for continuous columnar-grained (CCG) polycrystalline copper at room temperature, which was cold-drawn from a 10-mm-diameter as-cast rod into a 38.5-μm-diameter ultra-fine wire without any intermediate softening heat treatment. During the extreme plastic deformation, the ultimate tensile stress increased from 140 MPa for as-cast CCG copper to 525 MPa for the deformed sample at a true stain of 11.12, while the relative electrical conductivity maintained a high value of 97.6% IACS. On this basis, CCG copper is an excellent raw material for the fabrication of ultra-fine wires with both high strength and high electrical conductivity. The original columnar grains experienced grain subdivision and formed fibrous grains along the drawing direction with a fibrous longitudinal morphology and curly transverse microstructure at medium to high strain. The subdivision of the fibrous grains then went on as the extreme plastic deformation continued. Large amounts of strain-induced boundaries and microstructural refinement facilitated the storage of abundant glide dislocations created by extreme plastic deformation. Thus, extreme plastic extensibility can be achieved through continuous work hardening of CCG copper.

36 MATERIALS SCIENCE↗