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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 1,117 records · Page 62
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

A Review on Friction Stir Processing of Titanium Alloy: Characterization, Method, Microstructure, Properties

In the past two decades, friction stir processing (FSP) technology has received considerable attention. FSP can be used to adjust and control the microstructure of materials, including eliminating defects, destroying dendrites and controlling fractions in the second stage, and is therefore widely used in titanium and its alloys for biomedical, aerospace and automotive applications. This article comprehensively reviews the methods of studying FSP, the microstructure evolution of materials and the summary of material properties. It begins with the introduction of the FSW system, characterization, structure and elemental analysis, and simulation and performance testing methods, and then introduces the microstructure evolution mechanism of various titanium materials and discusses in detail the material properties of titanium alloy, namely hardness and wear resistance, elasticity and plasticity, corrosion resistance and biocompatibility. Finally, this review presents unresolved issues and outstanding challenges in FSP technology and reveals the direction of this emerging field of research.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Microstructure and in-service degradation of baffle former bolts – in-core components of light water reactors

This report presents a microstructure evaluation of the baffle former bolt, a commercial pressurized water reactor component. Using SEM, EDS, and EBSD analysis the material was identified as AISI 316 steel with an annealed austenite microstructure. Findings include abnormal grain growth in a fraction of the grains and the absence of retained ferrite. Notable observations include an overlapping of pre- and post-irradiation deformation, including defect-free channel formation as an active deformation mechanism in the near-surface layer of BFB. Specimen surfaces, exposed to high-temperature, high-pressure water, exhibited signs of in-service corrosion degradation. EBSD and EDS analyses highlighted intergranular corrosion, possible grain boundary oxidation with depths less than 3 µm, and, unexpectedly, short cracks filled with Cr-rich oxides measuring around 5-6 µm. The presence of defect-free channels from EBSD data suggests episodes of high mechanical stresses during service. The specimens provide a potentially unique insight into the in-service degradation of NPP components, strain localization, and crack initiation processes. An intact corrosion layer reveals a complex component's in-service history. Further research is underway for a detailed analysis.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2018

Reduced-order microstructure-sensitive protocols to rank-order the transition fatigue resistance of polycrystalline microstructures

We present that the transition fatigue regime between low cycle fatigue (LCF) and high cycle fatigue (HCF) is often addressed in the design and performance evaluation of load-bearing components used in many structural applications. Transition fatigue is characterized by elevated levels of local inelastic deformation in significant regions of the microstructure as compared to HCF. Typically, crystal plasticity finite element method (CPFEM) simulations are performed to model this phenomenon and to rank-order microstructures by their resistance to crack formation and early growth in the regime of transition fatigue. Unfortunately, these approaches require significant computational resources, inhibiting their use to explore novel materials for transition fatigue resistance. Reduced-order, microstructure-sensitive models are needed to accelerate the search for next-generation, fatigue-resistant materials. In a recent study, Paulson et al. (2018) extended the materials knowledge system (MKS) framework for rank-ordering the HCF resistance of polycrystalline microstructures. The efficacy of this approach lies in the reduced-dimensional representation of microstructures through 2-point spatial correlations and principal component analysis (PCA), in addition to the characterization of the HCF response with a small set of performance measures. In this work, these same protocols are critically evaluated for their applicability to rank-order the transition fatigue resistance of the same class of polycrystalline microstructures subjected to increased strain amplitudes. Success in this endeavor requires the formation of homogenization linkages that account for the significantly higher levels of local inelastic deformation and stress redistribution in transition fatigue as compared to HCF. Finally, a set of 12 α-titanium microstructures generated using the open access DREAM.3D software (Groeber and Jackson, 2014) are employed for this evaluation.

2-point correlations↗
DOE OSTI2017

A 3D contact analysis approach for the visualization of the electrical contact asperities

The electrical contact is an important phenomenon that should be given into consideration to achieve better performance and long term reliability for the design of devices. Based upon this importance, the electrical contact interface has been visualized as a “3D Contact Map” and used in order to investigate the contact asperities. The contact asperities describe the structures above and below the contact spots (the contact spots define the 3D contact map) to the two conductors which make the contact system. The contact asperities require the discretization of the 3D microstructures of the contact system into voxels. A contact analysis approach has been developed and introduced in this paper which shows the way to the 3D visualization of the contact asperities of a given contact system. For the discretization of 3D microstructure of contact system into voxels, X-ray Computed Tomography (CT) method is used in order to collect the data of a 250 V, 16 A rated AC single pole rocker switch which is used as a contact system for investigation.

47 OTHER INSTRUMENTATION↗
DOE OSTI2015

Nano-chemo-mechanical signature of conventional oil-well cement systems: Effects of elevated temperature and curing time

With ever more challenging (T,p) environments for cementing applications in oil and gas wells, there is a need to identify the fundamental mechanisms of fracture resistant oil well cements. We report results from a multi-technique investigation of behavior and properties of API class G cement and silica-enriched cement systems subjected to hydrothermal curing from 30 °C to 200 °C; including electron probe microanalysis, X-ray diffraction, thermogravimetry analysis, electron microscopy, neutron scattering (SANS), and fracture scratch testing. The results provide a new insight into the link between system chemistry, micro-texture and micro-fracture toughness. We suggest that the strong correlation found between chemically modulated specific surface and fracture resistance can explain the drop in fracture properties of neat oil-well cements at elevated temperatures; the fracture property enhancement in silica-rich cement systems, between 110° and 175 °C; and the drop in fracture properties of such systems through prolonged curing over 1 year at 200 °C.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Composition and microstructure of zirconium and hafnium germanates obtained by different chemical routes

The phase composition and morphology of zirconium and hafnium germanates synthesized by ceramic and co-precipitation routes were studied. The products were characterized using high-temperature X-ray diffraction analysis (XRD), Raman spectroscopy, scanning electron microscopy (SEM) and thermal (TG/DTA) analysis. To investigate the phase composition and stoichiometry of compounds the unit cell parameters were refined by full-profile Rietveld XRD analysis. The morphology of products and its evolution during high-temperature treatment was examined by SEM analysis. It was stated that there is the strong dependence of the phase composition and morphology of products on the preparation route. The ceramic route requires a multi-stage high-temperature treatment to obtain zirconium and hafnium germanates of 95% purity or more. Also, there are strong diffusion limitations to obtain hafnium germanate Hf{sub 3}GeO{sub 8} by ceramic route. On the contrary, the co-precipitation route leads to the formation of nanocrystalline single phase germanates of stoichiometric composition at a relatively low temperatures (less than 1000 °C). The results of quantitative XRD analysis showed the hafnium germanates are stoichiometric compounds in contrast to zirconium germanates that form a set of solid solutions. This distinction may be related to the difference in the ion radii of Zr and Hf. - Graphical abstract: The phase composition and morphology of zirconium and hafnium germanates synthesized by ceramic and co-precipitation routes were studied. It was stated that there is the strong dependence of the phase composition and morphology of products on the preparation route. Display Omitted - Highlights: • Zr and Hf germanates were synthesized by ceramic and co-precipitation routes. • The morphology of products depends on the synthesis parameters. • Zirconium germanates forms a set of solid solutions. • Hafnium germanates are stoichiometric compounds.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2019

Nanoscale analysis of ion irradiated ODS 14YWT ferritic alloy

In this work, the nanoscale microstructure of an advanced oxide dispersion strengthened (ODS) 14YWT ferritic alloy (SM13 heat) with nominal composition Fe–14Cr–3W-0.4Ti-0.3Y 2 O 3 (wt. %) has been characterized by atom probe tomography (APT) before and after ion irradiation with 70 MeV Fe 9+ ions at 450 °C to a total dose of 21 dpa. A detailed solute cluster analysis of APT data reveals that, in the manufacturing process, larger nanoparticles form in or close to the grain boundaries respective to those inside grains. The evolution of the nanoparticles after irradiation seems to be related to their location, as a higher increase in the number density and in the Y:Ti ratio is observed for the nanoparticles in or close to grain boundaries. Furthermore, APT analysis also shows Cr, W and C segregation to grain boundaries enhanced by the irradiation. A previous study of this same alloy before and after irradiation reports that the mechanical properties do not seem to be affected, but the microstructure was not investigated to confirm. The present work confirms little microstructural evolution after irradiation in this 14YWT alloy, indicating tolerance at the given irradiation conditions.

14YWT↗
NASA NTRS2000

Mineralogy and Microstructures of Shock-Induced Melt Veins in Chondrites

The applicability of phase equilibrium data to the interpretation of shock-induced melt veins can only be tested by a detailed study of melt- vein mineralogy to see how high-pressure assemblages vary as a function of shock conditions inferred from other indicators. We have used transmission electron microscopy (TEM), analytical electron microscopy (AEM), scanning electron microscopy (SEM), electron microprobe analysis (EMA) and optical petrography to characterize the mineralogy, microstructures, and compositions of melt veins and associated high-pressure minerals in shocked chondrites and SNC meteorites. In the processes, we have gained a better understanding of what melt veining can tell us about shock conditions and we have discovered new mineral phases in chondritic and SNC meteorites.

Sharp, Thomas G.↗
DOE OSTI2016

The microstructure of the surface layer of magnesium laser alloyed with aluminum and silicon

The surface layer under analysis was formed as a result of diffusion bonding of a thin AlSi20 plate to a magnesium substrate followed by laser melting. Depending on the process parameters, the laser beam melted the AlSi20 plate only or the AlSi20 plate and a layer of the magnesium surface adjacent to it. Two types of microstructure of the remelted layer were thus analyzed. If the melting zone was limited to the AlSi20 plate, the microstructure of the surface layer was typical of a rapidly solidified hypereutectic Al–Si alloy. Since, however, the liquid AlSi20 reacted with the magnesium substrate, the following intermetallic phases formed: Al{sub 3}Mg{sub 2}, Mg{sub 17}Al{sub 12} and Mg{sub 2}Si. The microstructure of the modified surface layer of magnesium was examined using optical, scanning electron and transmission electron microscopy. The analysis of the surface properties of the laser modified magnesium revealed that the thin layer has a microstructure of a rapidly solidified Al–Si alloy offering good protection against corrosion. By contrast, the surface layer containing particles of intermetallic phases was more resistant to abrasion but had lower corrosion resistance than the silumin type layer. - Highlights: •A CO{sub 2} laser was used for surface alloying of Mg with AlSi20. •Before alloying, an AlSi20 plate was diffusion bonded with the Mg substrate. •The process parameters affected the alloyed layer microstructure and properties. •With melting limited to AlSi20, the layer had a structure of rapidly solidified AlSi20. •Mg–Al and Mg–Si phases were present when both the substrate and the plate were melted.

36 MATERIALS SCIENCE↗
NASA NTRSDate not supplied

Modeling the Stochastic Response of Fiber Reinforced Composites with Varied Representative Volume Element Sizes

Fiber reinforced composites are desirable in applications where low weight and high strength are needed, but are susceptible to variability and flaws during manufacturing, making failure predictions difficult. These flaws may occur at the microscale where mechanical properties vary locally due to regions of fiber clusters and matrix pockets. In this study, a multiscale approach was taken to model 3-point bend, 4-point bend, and tensile experiments of a unidirectional composite from only having microstructure scans of these samples and constituent properties from literature. These scans were sampled with different sized windows, and statistically equivalent microstructures were generated, then simulated for stiffness, strength, and fracture toughness using a reduced order micromechanical model and NASA’s Multiscale Analysis Tool (NASMAT). Mesoscale models were created with equivalent element sizes to microstructures and properties sampled from microscale simulation results. Results showed how microscale size affects certain mechanical properties. Also shown is how well mesoscale models agree to experiments when using stochastic element properties and varying element size.

microstructure↗
DOE OSTI2021

Deterioration mechanism of alkali-activated materials in sulfuric acid and the influence of Cu: A micro-to-nano structural, elemental and stable isotopic multi-proxy study

In this study, a multi-proxy approach combining {sup 29}Si, {sup 27}Al and {sup 1}H MAS-NMR, FEG-EPMA, XANES at the Cu K-edge and XRD analytics with hydrochemical tools such as ICP-OES analyses, oxygen-isotope signatures, and thermodynamic modelling was applied to K-silicate-activated metakaolin specimens - with and without CuSO{sub 4}·5H{sub 2}O addition - exposed to sulfuric acid at pH = 2 for 35 days. The results revealed a multistage deterioration mechanism governed by (i) acid diffusion, (ii) leaching of K-A-S-H, (iii) microstructural damage related to precipitation of expansive (K,Ca,Al)-sulfate-hydrate phases (iv) complete dissolution of the K-A-S-H framework, (v) and formation of silica gel in the outermost corroded regions. Copper ions were mainly located in layered spertiniite-chrysocolla-like phases in the as-cured materials. The results demonstrate an overall negative effect of Cu addition on chemical material durability, implying that the reported higher durability of Cu-doped AAM in biocorrosion environments can be best explained by bacteriostatic effects.

36 MATERIALS SCIENCE↗
NASA NTRS1972

Use of LEED, Auger emission spectroscopy and field ion microscopy in microstructural studies

Surface research tools such as LEED, Auger emission spectroscopy analysis, and field ion microscopy are discussed. Examples of their use in studying adhesion, friction, wear, and lubrication presented. These tools have provided considerable insight into the basic nature of solid surface interactions. The transfer of metals from one surface to another at the atomic level has been observed and studied with each of these devices. The field ion microscope has been used to study polymer-metal interactions and Auger analysis to study the mechanism of polymer adhesion to metals. LEED and Auger analysis have identified surface segregation of alloying elements and indicated the influence of these elements in metallic adhesion. LEED and Auger analysis have assisted in adsorption studies in determining the structural arrangement and quantity of adsorbed species present in making an understanding of the influence of these species on adhesion possible. These devices are assisting in the furtherance of understanding of the fundamental mechanism involved in the adhesion, friction, wear, and lubrication processes.

Ferrante, J.↗
NASA NTRS1994

Analysis of small crack behavior for airframe applications

The small fatigue crack problem is critically reviewed from the perspective of airframe applications. Different types of small cracks-microstructural, mechanical, and chemical-are carefully defined and relevant mechanisms identified. Appropriate analysis techniques, including both rigorous scientific and practical engineering treatments, are briefly described. Important materials data issues are addressed, including increased scatter in small crack data and recommended small crack test methods. Key problems requiring further study are highlighted.

Mcclung, R. C.↗
DOE OSTI2026

Affine Transformations to Enable Machine Learning for Semi-Quantitative EDS Analysis

Energy Dispersive X-ray Spectroscopy (EDS) is an essential technique for determining elemental concentrations and distributions within microstructures, critical for materials discovery, optimization, and qualification. However, most published EDS data is qualitative because current quantitative EDS analysis methods require extensive calibration and post-processing, limiting their practicality and widespread adoption. This work seeks to establish a framework for accelerated EDS characterization and spectrum analysis that can leverage ML to analyze correlations between various elemental compositions and resulting EDS spectra. The complex physics and data result in a high-dimensional problem that grows exponentially with the number of elements in the system and the complexity of the spectrum analysis. ML provides a way to compute and optimize the results of this highly dimensional problem in a flexible way to tailor it to the user’s specific needs and material system. However, the framework emphasizes transparency through a strictly mathematical affine transformation, so the analysis remains understandable and reviewable to facilitate adoption by the scientific community. While currently implemented methods are simplistic and unvalidated, further development and demonstration of this framework could enable high-throughput, accurate, and accessible EDS characterization.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

Influence of finish rolling temperature on the microstructure and mechanical properties of Mg-8.5Al-0.5Zn-0.2Mn-0.15Ag alloy sheets

Highlights: • The microstructure is strongly depending on the finish rolling temperature. • Extensive shear zones parallel distributed across the sheets. • The formation process of shear zones in RH and RL are different. • Shear zones decide the mechanical anisotropy of the whole sheet. - Abstract: Mg-8.5Al-0.5Zn-0.2Mn-0.15Ag (wt%) magnesium sheets were produced with various final rolling temperatures, and their microstructures and mechanical properties were characterized. It was found that low final rolling temperature (LT) resulted in stronger heterogeneity, stronger basal texture and higher strength compared with the high final rolling temperature (HT). Considerable shear zones were observed within both the LT and HT sheets, even though their microstructures, formation mechanisms and mechanical properties were different. Preliminary analysis suggests that the shear zones exert great influence on the mechanical anisotropy of whole sheets.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Effect of Cooling Rate on Microsegregation During Solidification of Superalloy INCONEL 718 Under Slow-Cooled Conditions

The solidification sequence, microstructural evolution, solid-liquid interface variation, interdendritic segregation, and elemental distribution of as-cast IN718 alloy at three slow-cooling rates (5, 10, and 20 °C/min) were investigated by differential scanning calorimetry (DSC), confocal laser scanning microscopy (CLSM), optical microscopy (OM), field-emission scanning electron microscopy (FESEM), and electron-probe microanalysis (EPMA) techniques. The results indicate that as the cooling rate decreases, the constitutional supercooling at the solidification front affects the solid-liquid interface more significantly, and the size and quantity of the Laves phase increase. However, the composition of the Laves phase is insensitive to the cooling rate in the range of conditions studied here. In dendrite core, the contents of Ni, Cr, Fe, and Al follow a slight downward trend with an increasing cooling rate, whereas the Nb, Mo, and Ti contents show an upward trend. Additionally, Mo shows a stronger propensity to segregate under slow-cooling conditions because its effective partition coefficient almost linearly decreased with decreasing cooling rate, which is same as Nb. Using the parameters experimentally determined in this study and the Clyne–Kurz equation, we achieved reasonable agreement between the calculated and measured liquid composition change during the solidification process at different cooling rates. All experimental and theoretical programs in this research were undertaken with the aim of gaining further understanding of the microsegregation behaviors in large-scale IN718 ingots, whose cooling rates are within a lower range.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Post-irradiation examination of AGR-3/4 TRISO fuel compacts using three-dimensional X-ray computed tomography

The AGR-3/4 irradiation tests combined the third and fourth planned irradiation experiments in the US Department of Energy’s Advanced Gas Reactor (AGR) testing campaign of tri-structural isotropic (TRISO) fuel compacts. In this article, we present post-irradiation examination (PIE) using X-ray computed tomography (XCT) of two unirradiated and two irradiated compacts from the AGR-3/4 irradiation tests. The irradiated compacts studied (compact 7–1 and compact 12–4) represent the upper and lower limit of burnup within the AGR-3/4 irradiation experiment. This article presents a detailed quantitative analysis on the post-irradiation structure of TRISO fuel compacts. Various quantitative parameters including shape, size, and packing of kernels, and their spatial distribution, were utilized to gain insights into the structural changes caused by irradiation. The equivalent diameter and sphericity were found to increase and decrease, respectively, in irradiated compact 7–1 due to its higher burnup. Nearest neighbor distance between fuel kernels decreased after irradiation, suggesting irradiation-induced shrinkage of graphitic matrix. Furthermore, each compact in AGR-3/4 irradiation tests contained 20 designed-to-fail (DTF) fuel particles that were meant to act as a source of fission product release to the experiment test train. Furthermore, in the present work, all DTF fuel particles in the four compacts studied were identified, and it was found that they exhibited larger kernel swelling in compact 12–4 and smaller kernel swelling in compact 7–1, compared to the driver particles.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗