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At least 1,099 records · Page 61
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Creep Behavior of Friction Stir Processed Haynes 282

Haynes 282 is a nickel-based superalloy designed for use in hot sections of turbines for aircraft and power generation. In these applications, elevated temperature creep performance is critical. To that end, creep behavior of friction stir processed material was carried out to investigate the high-temperature performance of this alloy. Friction stir processing of Haynes 282 was successfully completed, and the processed region was found to be defect-free. Various mechanical property characterization approaches were carried out in post-heat treated condition. Transverse tensile samples repeatedly failed in the base metal indicating 100% joint efficiency. Creep property evaluation was completed at 760 °C and at various stress levels. The creep-rupture lifetime of the processed material was similar to the base metal. Detailed electron microscopy analysis of the failed sample was carried out to understand the microstructural evolution in various locations of the sample during creep.

creep↗
DOE OSTI2026

Enhanced accuracy through ensembling of randomly initialized auto-regressive models for dynamical systems

Computational mechanics simulations using traditional finite element methods (FEM) require prohibitively expensive computational resources for real-time engineering applications, design optimization, and digital twin implementations. While machine learning (ML) surrogate models offer significant computational speedups, autoregressive ML models for time-dependent mechanical systems suffer from error accumulation that compromises long-term prediction reliability - a critical concern for engineering applications where accuracy over extended time horizons is essential for safety and performance assessments. Here, we propose a deep ensemble framework specifically designed to address this challenge in computational mechanics applications, where multiple ML surrogate models with random weight initializations are trained in parallel and their predictions aggregated during inference. This approach leverages statistical diversity to maximize information gain from a fixed set of training data and to mitigate error propagation, while maintaining the computational efficiency that makes ML surrogates attractive for engineering practice. We validate the framework on three representative problems spanning critical areas of computational mechanics: stress field evolution in heterogeneous microstructures under complex loading (relevant to advanced materials design and composite analysis), planetary-scale shallow water dynamics (applicable to environmental and geotechnical engineering), and Gray-Scott reaction-diffusion systems (relevant to mass transport and chemical process engineering). Across all test cases, the ensemble approach demonstrates consistent error reduction of 15-33% compared to individual models. The codes for this work are available on GitHub (https://github.com/Graham-Brady-Research-Group/AutoregressiveEnsemble_SpatioTemporal_Evolution).

autoregressive prediction↗
DOE OSTI2024

Understanding interfacial crystallization dynamics on carbon fiber reinforced polypropylene composite manufacturing

Reinforcing polymers with discontinuous fibers improves mechanical properties, such as strength and stiffness, and in some cases achieve isotropic properties, rendering them suitable for various engineering applications. Matrix materials are generally highly engineered thermosets (e.g. crosslinked epoxies), bonded to the fiber periphery by proprietary surface and sizing chemistries. Semicrystalline thermoplastic matrices are less utilized due to poor fiber-matrix bonding resulting in inefficient interfacial load-transfer in reinforced composites. However, flexibility with melt-processing or molding conditions can be leveraged to promote non-covalent interfacial bonding between matrix and fiber via crystallization of the matrix onto fiber surface. In the present study, we utilize a co-mingle chopped carbon and isotactic polypropylene fibers to form isotropic composites, tailoring interfacial immobilized matrix or interphase morphology to optimize performance through precise control of thermal processing/molding windows. Calorimetry and optical microscopy were employed to investigate the impact of carbon fiber at various volume fractions (10, 20, and 30 %) on isotactic polypropylene crystallization and mechanical performance. Variations in mechanical properties correspond to the structural evolution of the interfacial region and are correlated to underlying microstructural attributes using wide-angle X-ray scattering, thermal analysis, and low-field nuclear magnetic resonance spectroscopy. These results provide a practical framework for the manufacturing of thermoplastic matrix composites. In conclusion, the results presented provide a guide for the strategic optimization of interphase design, showcasing tailorable tensile strengths which outperform any isotactic polypropylene carbon fiber composites previously reported in literature.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Review of SiC material development for nuclear fusion applications: Cross-cutting research and emerging opportunities

The SiC-based materials, particularly SiC-fiber-reinforced SiC matrix (SiC/SiC) composites, show strong potential for structural and functional applications in future fusion power plants because they can operate at high temperatures with a range of coolants and breeders, thereby enabling higher energy conversion efficiency. Here, this paper presents recent advancements in the development of SiC-based materials, focusing on processing techniques and material performance and resistance under fusion-relevant environments. The processing activities have emphasized near-net-shape fabrication and the joining of SiC subcomponents, with processing methods and material compositions informed by previous irradiation experiments on various grades of SiC. Research on irradiation effects has remained focused on degradation mechanisms and the microstructural optimization of SiC/SiC composites irradiated to high neutron damage levels. Analysis of irradiation defects in SiC has advanced via the application of cutting-edge characterization methods, among which Raman spectroscopy is becoming a common tool to assess atomic-scale chemical disorder. Fusion–fission crosscutting irradiation research has explored combined effects in SiC/SiC composites with application-relevant geometries, including bowing of SiC/SiC composite channels under neutron flux gradients, stress evolution in SiC/SiC composite tubes under through-thickness temperature gradients, and irradiation-enhanced corrosion in SiC. Finally, research opportunities for component testing and assessment under fusion-relevant conditions, in support of emerging concepts from the private fusion sector, are discussed.

Advanced manufacturing↗
DOE OSTI2013

A carbon foam with a bimodal micro–mesoporous structure prepared from larch sawdust for the gas-phase toluene adsorption

Highlights: ► Network carbon foam containing a bimodal pore distribution was prepared from Larch. ► Liquefaction route was used for the preparation of morphology controllable carbon. ► Pore structure of carbon foam was controlled through KOH activation. - Abstract: A carbon foam with a bimodal micro–mesopore distribution, was prepared by submitting larch sawdust to liquefaction, resinification, foaming, carbonization and KOH activation. The morphology, pore texture and crystal microstructure was characterized by scanning and transmission electron microscopy, nitrogen adsorption analysis and X-ray powder diffraction. A honeycomb structure with adjacent cells was observed for the precursor of carbon foam. After KOH activation, the cell wall of precursor shrunk and broke. This lead to the formation of a well-connected 3D network and developed ligament pore structure (surface area of 554–1918 m{sup 2}/g) containing bimodal pores, 2.1 and 3.9 nm in diameter. The porous carbon foam prepared at 700 °C exhibited a much higher gas-phase toluene removal than commercial activated carbon fiber owing to the 3D network and bimodal pore structure.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Stochasticity at Scales Leads to Lithium Intercalation Cascade

Porous intercalation electrodes are synonymous with the promise of lithium-ion batteries toward electromobility. These electrodes exhibit stochastic geometrical features spanning different length scales. The implication of microstructural inhomogeneity on the lithium intercalation dynamics is hitherto unknown. In this work, starting from three-dimensional (3D), X-ray tomograms of intercalation electrode microstructures, we characterize the microstructural variability in porous intercalation electrodes. Furthermore, a physics-based analysis of electrochemical response reveals that the stochastic features can cause preferential lithiation fronts.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2014

Optical waveguiding properties into porous gallium nitride structures investigated by prism coupling technique

In order to modulate the refractive index and the birefringence of Gallium Nitride (GaN), we have developed a chemical etching method to perform porous structures. The aim of this research is to demonstrate that optical properties of GaN can be tuned by controlling the pores density. GaN films are prepared on sapphire by metal organic chemical vapor deposition and the microstructure is characterized by transmission electron microscopy, and scanning electron microscope analysis. Optical waveguide experiment is demonstrated here to determine the key properties as the ordinary (n{sub 0}) and extraordinary (n{sub e}) refractive indices of etched structures. We report here the dispersion of refractive index for porous GaN and compare it to the bulk material. We observe that the refractive index decreases when the porous density p is increased: results obtained at 0.975 μm have shown that the ordinary index n{sub 0} is 2.293 for a bulk layer and n{sub 0} is 2.285 for a pores density of 20%. This value corresponds to GaN layer with a pore size of 30 nm and inter-distance of 100 nm. The control of the refractive index into GaN is therefore fundamental for the design of active and passive optical devices.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Inherent issues regarding the use of in situ x-ray diffraction measurements to determine temperature in shock-compressed metals

Temperature determination in shock compressed solids constitutes an important and long-standing scientific need. Since the reduction of Bragg diffracted peaks due to temperature increase, using the Debye-Waller factor, is well established, we examined the use of this approach to determine temperatures in shock compressed gold and platinum by representing the shocked state as a superposition of density and temperature changes. Comparison of the calculated and measured diffraction peaks did not show good agreement, because x-ray diffraction (XRD) profiles in the shock compressed state are not governed solely by density and temperature changes. XRD results are also influenced measurably by shock wave induced microstructural changes. Our results demonstrate that contributions from microstructural changes need to be incorporated and modeled in the theoretical analysis to use XRD measurements for reliable temperature determination in shock compressed solids.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2021

Elastic and thermodynamic properties of cerium-doped yttrium aluminum garnets

Cerium-doped yttrium aluminum garnets (Y 3-x Ce x Al 5 O 12 , Ce:YAGs) are promising yellow light-emitting components of solid-state white light-emitting diodes. Although there have been numerous studies examining the effects of Ce concentrations on the luminescent properties of Y 3-x Ce x Al 5 O 12 , the impacts of Ce dopant on the elastic and thermodynamic properties are not well understood. In this work, we used resonant ultrasound spectroscopy (RUS) to determine the effects of Ce doping (0.025, 0.1, 1 at. %) on the elastic and thermodynamic properties of Y 3-x Ce x Al 5 O 12 . The elastic moduli calculated via the Voigt–Reuss–Hill (VRH) method demonstrated that low Ce dopant concentrations (≤0.1 at. %) induced negligible effects on the elasticity of the YAG host matrix, while a high Ce concentration (1 at. %) yielded significant softening. RUS spectral analysis and SEM images suggested that the elastic softening originated from microstructural differences induced at higher Ce dopant concentrations. Additionally, we demonstrated an increase in elastic anisotropy at higher Ce concentrations, which further elucidated the correlations between structure and elasticity of Y 3-x Ce x Al 5 O 12 . Debye temperatures ($θ_D$), heat capacities ($C_p$), and thermal conductivities ($\mathit{κ}$) were calculated for Ce:YAGs through the relations of RUS-derived parameters (sound velocities, elastic moduli) and previously determined thermal expansion coefficients. Ce:YAG was found to have a significant reduction in $θ_D$, Cp, and $\mathit{κ}$ at Ce concentrations ≥1 at. %. Lastly, extrapolation of $C_p$ and $\mathit{κ}$ to higher temperatures allowed the modeling of thermal stress experienced by Y 3-x Ce x Al 5 O 12 disks up to 1073.15 K.

36 MATERIALS SCIENCE↗
DOE OSTI2025

PyCMG-based Simulation of Volumetric Concrete Microstructure

Concrete is a complex, heterogeneous material with a microstructure composed of aggregates, cement paste, and pores spanning multiple length scales. Understanding this microstructure is critical for advancing the performance, durability, and modeling of concrete-based systems. While experimental imaging such as X-ray computed tomography (XCT) provides valuable insights, generating large datasets with detailed ground truth annotations is both costly and labor-intensive due to challenges in segmenting similar phases, such as aggregates and cement paste, that often share similar attenuation properties. To address this, we developed a pipeline to simulate realistic 3D concrete microstructures using the open-source Python package PyCMG. This simulation effort focuses on generating high-fidelity, annotated microstructures that can serve as training or benchmarking datasets for image analysis, segmentation algorithms, and machine learning models, particularly in scenarios where experimental data is scarce.

Ziabari, Amir [Oak Ridge National Laboratory; ORNL↗
DOE OSTI2016

AGR-1 Compact 4-1-1 Post-Irradiation Examination Results

Destructive post-irradiation examination was performed on AGR-1 fuel Compact 4-1-1, which was irradiated to a final compact-average burnup of 19.4% FIMA (fissions per initial metal atom) and a time-average, volume-average temperature of 1072°C. The analysis of this compact focused on characterizing the extent of fission product release from the particles and examining particles to determine the condition of the kernels and coating layers. The work included deconsolidation of the compact and leach-burn-leach analysis, visual inspection and gamma counting of individual particles, metallurgical preparation of selected particles, and examination of particle cross-sections with optical microscopy, electron microscopy, and elemental analysis. Deconsolidation-leach-burn-leach (DLBL) analysis revealed no particles with failed TRISO or failed SiC layers (as indicated by very low uranium inventory in all of the leach solutions). The total fractions of the predicted compact inventories of fission products Ce-144, Cs-134, Cs-137, and Sr-90 that were present in the compact outside of the SiC layers were <2×10 -6 , based on DLBL data. The Ag-110m fraction in the compact outside the SiC layers was 3.3×10 -2 , indicating appreciable release of silver through the intact coatings and subsequent retention in the OPyC layers or matrix. The Eu-154 fraction was 2.4×10 -4 , which is equivalent to the inventory in one average particle, and indicates a small but measurable level of release from the intact coatings. Gamma counting of 61 individual particles indicated no particles with anomalously low fission product retention. The average ratio of measured inventory to calculated inventory was close to a value of 1.0 for several fission product isotopes (Ce-144, Cs-134, and Cs-137), indicating good retention and reasonably good agreement with the predicted inventories. Measured-to-calculated (M/C) activity ratios for fission products Eu-154, Eu-155, Ru-106, Sb-125, and Zr-95 were significantly less than 1.0. However, as no significant release of these fission products from compacts was noted during previous analysis of the AGR-1 capsule components, the low M/C ratios are most likely an indication of a bias in the inventories predicted by physics simulations of the AGR-1 experiment. The distribution of Ag-110m M/C ratios was centered on a value of 1.02 and was fairly broad (standard deviation of 0.18, with values as high as 1.42 and as low as 0.68). Based on all data gathered to date, it is believed that silver retention in the particles was on average relatively high, but that the broad distribution in values among the particles represents significant variation in the inventory of Ag-110m generated in the particles. Ceramographic analysis of particle cross-sections revealed many of the characteristic microstructures often observed in irradiated AGR-1 particles from other fuel compacts. Palladium-rich fission product clusters were observed in the IPyC and SiC layers near the IPyC-SiC interface of three Compact 4-1-1 particle cross-sections. In spite of the presence of fission product clusters in the SiC layer, no significant corrosion or degradation of the layer was observed in any of the particles examined.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2016

Collaboration for the Advancement of Indirect 3D Printing Technology

Amorphous powders often possess high hardness values and other useful mechanical properties. However, densifying these powders into complex shapes while retaining their unique properties is a challenge with standard processing routes. Pressureless sintering, for example, can densify intricate green parts composed of rapidly-solidified powders. But this process typically involves long exposures to elevated temperatures, during which the non-equilibrium microstructure of the powder can evolve towards lower energy configurations with inferior properties. Pressure-assisted compaction techniques, by contrast, can consolidate green parts with simple shapes while preserving the microstructure and properties of the powder feedstock. But parts made with these processes generally require additional post-processing, including machining, which introduces new challenges due to the high hardness of these materials. One processing route that can potentially avoid these issues is Indirect 3D Printing (I-3DP; aka Binder Jetting) followed by melt infiltration. In I-3DP, an organic binder is used to join powder feedstock, layer-by-layer, into a green part. In melt infiltration, this green preform is densified by placing it in contact with a molten alloy that wets the preform and wicks into the pores as a result of capillary forces. When these processes are paired together, they offer two key advantages for the densification of rapidly-solidified powders. The first advantage is that the timescale associated with melt infiltration is on the order of seconds for parts with cm-scale dimensions. So in many instances, infiltration requires only a brief thermal excursion that does not degrade the feedstock’s microstructure. The second advantage is that the combination of binder-jet 3D printing and melt infiltration gives fully-dense net shape objects, minimizing the need for subsequent post-processing. In this work, fully-dense, net shape objects have been fabricated from an amorphous powder using I-3DP and molten bronze infiltration while maintaining the amorphous microstructure. X-ray diffraction, scanning electron microscopy, and differential thermal analysis were used to characterize the structural evolution of the powder feedstock during an infiltration heating cycle. Microindentation and bend tests were performed on the infiltrated material to evaluate its mechanical properties. It was found that infiltration improved both the ductility and strength of the sintered preforms by eliminating the stress concentration at the interparticle necks. The infiltrated material had an 11 GPa Vickers hardness and moderate damage tolerance, making it well-suited for applications requiring hard, net shape parts.

42 ENGINEERING↗
DOE OSTI2021

Post Examination of Candidate NpO 2 Targets for 238 Pu Production

Four targets composed of sintered NpO 2 pellets enclosed in Zircaloy cladding were irradiated in the High Flux Isotope Reactor for 2 to 4 cycles to determine if an oxide pellet and Zircaloy cladding would be usable candidates for 238 Pu production. The pellets were sintered to a high fraction of theoretical density (TD) and melt wires were placed in small holes that had been drilled in the center of selected pellets to determine if the pellet centers exceeded desirable operating temperatures. After irradiation, the targets were punctured to determine the internal target pressure and the fission gas release. None of the targets had excessive pressure, and fission gas release was in the range of 4 to 38%. The targets were then cut into segments for radiochemical analysis, and metallography (MET) mounts were created to examine the pellet microstructure and to search for the melt wires to determine if they had melted. Three of the four targets resulted in successful MET mounts; the two-cycle pellets were too friable to be handled. No signs of pellet melting were noted, and unfortunately, none of the melt wires could be recovered. The results indicate that this pellet/clad design offers a practical option for 238 Pu production.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Microbial Curing of Cement for Energy Applications

Rutgers University, Lawrence Livermore National Laboratory, and the University of Arizona executed this program over 36 months with a 4-Task Program: (M1)-Microbial Engineering (M2)-Microstructure Modelling, (M3) Cement and Concrete Formulation, (M4)-Techno-economic analysis (TEA) and lifecycle assessment (LCA). This program developed a new carbonate cement concrete manufacturing process called microbial curing (MBC). MBC utilizes in-situ microbial production of CO 2 that dissolves into pore-bound water to carbonate a cementitious material creating a bonding matrix of CaCO 3 and SiO 2 that hardens and densifies the material. This is the first work of this type where calcium silicate was used in microbial studies. All other work reported in the literature always used a soluble form of calcium. This final report describes the work done in the final quarter, the best procedures and results, and the final techno-economic and lifecycle analyses. This quarter, we cast and cured twenty-five (4”x8”) cylinder samples. The compressive strength, split tensile, Young’s modulus, chloride permeability, and creep measurements were performed. These measurements demonstrated that MBC of calcium silicate concrete exhibits scaling problems due to the escape of ammonia gas, a product of the microbial reaction to generate CO 2 . As curing proceeds, the ability for the gas to escape from within the cylinder is restricted by the outer cylindrical portions densifying, making the outer portion highly impermeable to gas flow. In contrast, the small samples cured are uniformly cured, forming materials whose mechanical properties are 7x better than the large samples. This problem needs to be solved before this technology can be commercialized. The techno-economic and lifecycle analyses indicate that the technology developed in this program exhibits a significant opportunity to reduce the cost of cement and CO 2 emissions associated with concrete, provided the curing issue associated with larger samples can be addressed.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Localized Strain Analysis of Ce- and Mg-Treated Cast Iron under Uniaxial Compression

Cast iron exhibits a wide range of mechanical properties, depending on its microstructural features. The microstructure of cast iron consists of several microconstituents with different elastic-plastic behavior, making the strain non-uniform across the bulk material. To understand the individual effects of these microconstituents on the overall mechanical behavior, local strain analysis using digital image correlation analysis was carried out. Samples with two different compositions (varying cerium, magnesium and silicon) were processed at different solidification velocities in a Bridgman furnace. Sections of the directionally solidified samples were loaded under uniaxial compression to measure global and local strain behavior. Despite the variability of the microstructure, the stress–strain curves obtained by digital image correlation (DIC) were found to react in a well-controlled way to changes in solidification velocity. It was observed that high-strain failure (greater than 15%) was accompanied by local straining of the softer ferritic phase, but during low-strain failure, local straining was not prominent. Higher nodularities, due to higher solidification velocities, raised the compressive strength without affecting the toughness significantly. Higher percentages of carbides led to higher compressive strengths with corresponding losses in ductility. The continuity of the matrix was also found to play an important role in the behavior during compression.

ductile failure↗
DOE OSTI2014

Microstructural, thermal and antibacterial properties of electron beam irradiated Bombyx mori silk fibroin films

The Bombyx mori silk fibroin (SF) films were prepared by solution casting method and the effects of electron beam on structural, thermal and antibacterial responses of the prepared films were studied. The electron irradiation for different doses was carried out using 8 MeV Microtron facility at Mangalore University. The changes in microstructural parameters and thermal stability of the films were investigated using Wide Angle X-ray Scattering (WAXS) and thermogravimetric analysis (TGA) respectively. Both microstructuralline parameters (crystallite size and lattice strain (g in %)) and thermal stability of the irradiated films have increased with radiation dosage. Agar diffusion method demonstrated the antibacterial activity of SF film which was increased after irradiation on both Gram-positive and Gram-negative species.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Experimental Study on the Hot Deformation Characterization of Low-Carbon Nb-V-Ti Microalloyed Steel

X80 steel, as typical low-carbon Nb-V-Ti microalloyed steel, is getting more and more attention in oil and gas transmission pipeline manufacturing. In this paper, the hot deformation behavior of X80 steel has been investigated. Hot compression tests of the steel were conducted under different temperatures and strain rates. Based on the experimental data, the flow stress constitutive equations were established. It is found that the hot deformation activation energy of this steel is higher than C-Mn and low-carbon steel. Then, the kinetics model and grain size model of dynamic recrystallization were developed according to the flow curves and the optical microstructures. In addition, the processing maps were developed to analyze the workability of X80 steel at elevated temperature. The analysis results show that the optimum processing window is at the temperature of 1300-1473 K and the strain rate of 0.01-10 s{sup −1}. The microstructure observation indicates that the optimum processing parameters are applicable to the tested steel.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Microstructural study of He{sup +}-implanted and thermally annealed silicon-on-sapphire layers

The effect of He{sup +} ion implantation and subsequent annealing on the silicon-on-sapphire microstructure is studied by transmission electron microscopy and X-ray diffraction analysis. It is established that He{sup +} ion implantation leads to the formation of defects in the Si layer and α-Al{sub 2}O{sub 3}, while subsequent annealing causes dissociation of radiation defects in Si and formation of nanopores in α-Al{sub 2}O{sub 3}. The effect of implanted-ion dose and annealing temperature on the parameters of the porous α-Al{sub 2}O{sub 3} layer and structural quality of the Si layer is investigated.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗