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At least 1,153 records · Page 64
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

A systematic study and framework of fringe projection profilometry with improved measurement performance for in-situ LPBF process monitoring

Fringe Projection Profilometry (FPP) is a cost-effective and non-invasive technology that has been shown to measure finer features. Here, in this work, we developed an in-situ FPP method to measure the dynamic topography of powder bed and printed layer during Laser Powder Bed Fusion (LPBF) additive manufacturing (AM) process. A systematic study towards developing a comprehensive framework of LPBF-specific FPP is demonstrated to enhance and evaluate the performance of applying FPP for in-situ LPBF monitoring, including 1) a modified sensor model with localized correction; 2) improved phase unwrapping with FFT filtering 3) quantitative uncertainty analysis; and 4) experimental validation with ex-situ characterization. The developed LPBF-specific FPP system and methods are implemented on a commercial LPBF-AM machine, achieving better accuracy, more robustness, and increased field of view while maintaining sufficient measurement range and decent resolution, in contrast to literature methods. The established FPP framework will facilitate the development of closed-loop control strategies for advancing LPBF based AM.

42 ENGINEERING↗
DOE OSTI2015

Synthesis, crystal structure and photoluminescence of (Ba{sub 0.99}Eu{sub 0.01})Al{sub 3}Si{sub 4}N{sub 9}

Crystalline grains of (Ba{sub 0.99}Eu{sub 0.01})Al{sub 3}Si{sub 4}N{sub 9} were obtained from samples synthesized by heating mixtures of binary nitride powders at 2000 °C and 0.85 MPa of N{sub 2} gas. The fundamental reflections of electron diffraction (ED) and X-ray diffraction (XRD) measured for some grains could be indexed with orthorhombic cell parameters: a=10.028(2) Å, b=53.353(9) Å, and c=5.9215(11) Å. Streaks and diffuse lines along the b axis were observed in the ED and XRD photographs, indicating stacking faults. A statistical average structure was analyzed using the intensity data of the fundamental reflections with the space group Fdd2. Local structure models were presented based on the average structure. Similar streaks and diffuse lines with fundamental reflections indexed with monoclinic cell parameters: a=5.8376(4) Å, b=26.6895(12) Å, c=5.8393(3) Å, and β=118.8428(15)° were also observed in the XRD oscillation photographs of another grain. The mixture of the grains having the orthorhombic and monoclinic fundamental structures emitted blue–green light with a peak wavelength of 500 nm and a full width at half-maximum (FWHM) of 65 nm under 400 nm excitation. The emission intensity measured at 300 °C was 67.5% of the intensity measured at 25 °C. A broad excitation band ranged from about 260 nm to 475 nm with maximum intensity at around 290 nm, and 60% of the intensity was obtained by excitation at 400 nm. - Graphical abstract: Crystalline grains of (Ba{sub 0.99}Eu{sub 0.01})Al{sub 3}Si{sub 4}N{sub 9}, having orthorhombic and monoclinic fundamental structures and stacking faults, were obtained from samples synthesized at 2000 °C and 0.85 MPa of N{sub 2}. The grains emitted blue–green light with a peak wavelength of 500 nm and a full width at half-maximum (FWHM) of 65 nm under 400 nm excitation. The emission intensity measured at 300 °C was 67.5% of the intensity measured at 25 °C. - Highlights: • (Ba{sub 0.99}Eu{sub 0.01})Al{sub 3}Si{sub 4}N{sub 9} was synthesized at 2000 °C and 0.85 MPa of N{sub 2}. • Stacking faults of the crystal structure were shown by X-ray and electron diffraction. • Orthorhombic and monoclinic statistical average-structure models were presented. • Photoluminescence excitation and emission spectra were measured. • Thermal quenching of the emission intensities was characterized.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2016

Defect Characterization for Material Assurance in Metal Additive Manufacturing (FY15-0664)

No industry-wide standards yet exist for minimum properties in additively manufactured (AM) metals. While AM alloys such as 17-4 precipitation hardened stainless steel have been shown to have average properties that can be comparable to wrought or cast product, they suffer from inconsistent performance. Variability in the feedstock powder, feature sizes, thermal history, and laser performance can lead to unpredictable surface finish, chemistry, phase content, and defects. To address this issue, rapid, efficient, high-throughput mechanical testing and data analysis was developed, providing profound statistical insight into the stochastic variability in properties. With this new approach, 1000’s of comprehensive tensile tests can be performed for the cost of 10’s of conventional tests. This new high-throughput approach provides a material qualification pathway that is commensurate with the quick turn-around benefit of AM.

36 MATERIALS SCIENCE↗
DOE OSTI2023

High pO2 Flux Growth and Characterization of NdNiO3 Crystals

Single crystals of the perovskite nickelate NdNiO3 with dimensions of up to 50 μm on edge have been successfully grown using the flux method at a temperature of 400 °C and oxygen pressure of 200 bar. The crystals were investigated by a combination of techniques, including high-resolution synchrotron X-ray single-crystal and powder diffraction and physical property measurements such as magnetic susceptibility and resistivity. Resistivity measurements revealed a metal-insulator transition (MIT) at TMIT~180 K with apparent thermal hysteresis; however, no superlattice peaks or peak splitting below TMIT, which corresponds to a structural transition from Pbnm to P21/n, was observed. The successful growth of NdNiO3 crystals at relatively low temperatures and oxygen pressure provides an alternative approach for preparing single crystals of interesting perovskites such as RNiO3 (R = Sm-Lu) and parent phases of superconducting square planar nickelates.

Wang, Xiaoli↗
DOE OSTI2017

Remotely sensed physical property estimation from powder contaminated surfaces

It is the intent of this paper to demonstrate the veracity of a method to estimate the total solid contaminant mass present on a sparsely coated surface encompassing a pixel from longwave infrared spectra. Sparsely coated surfaces create complex radiometry due to the interactions of electromagnetic energy between intimate materials. Current algorithms can be used on intimate mixtures to identify the abundances of materials in a pixel, but they cannot provide additional property information. Radiative transfer models can create mixture signatures, but only with a set of well-characterized physical parameters that are typically not known or are difficult to retrieve. Finally, the approach described here creates a parameter inversion model from a radiative transfer model and uses empirically measured mixture data to retrieve physical characteristics of the contaminated surface and derive a total contaminant mass present.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2016

Characterization of an aluminum alloy hemispherical shell fabricated via direct metal laser melting

The ability of additive manufacturing to directly fabricate complex shapes provides characterization challenges for part qualification. The orientation of the microstructures produced by these processes will change relative to the surface normal of a complex part. In this work, the microscopy and x-ray tomography of an AlSi10Mg alloy hemispherical shell fabricated using powder bed metal additive manufacturing are used to illustrate some of these challenges. The shell was manufactured using an EOS M280 system in combination with EOS-specified powder and process parameters. The layer-by-layer process of building the shell with the powder bed additive manufacturing approach results in a position-dependent microstructure that continuously changes its orientation relative to the shell surface normal. X-ray tomography was utilized to examine the position-dependent size and distribution of porosity and surface roughness in the 98.6% dense part. Optical and electron microscopy were used to identify global and local position-dependent structures, grain morphologies, chemistry, and precipitate sizes and distributions. The rapid solidification processes within the fusion zone (FZ) after the laser transit results in a small dendrite size. Cell spacings taken from the structure in the middle of the FZ were used with published relationships to estimate a cooling rate of ~9 × 10 5 K/s. Uniformly-distributed, nanoscale Si precipitates were found within the primary α-Al grains. A thin, distinct boundary layer containing larger α-Al grains and extended regions of the nanocrystalline divorced eutectic material surrounds the FZ. Moreover, subtle differences in the composition between the latter layer and the interior of the FZ were noted with scanning transmission electron microscopy (STEM) spectral imaging.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effects of build orientation and heat treatment on the evolution of microstructure and mechanical properties of alloy Mar-M-509 fabricated via laser powder bed fusion

We present the main results from an experimental investigation into the consequences of various microstructural features, created by laser powder bed fusion (LPBF) and subsequent heat treatments (HTs), in alloy Mar-M-509 on several aspects of plastic deformation including mechanical anisotropy and elongation-to-fracture (ETF). To ensure successful manufacturing of the alloy, porosity fraction and distribution are first characterized using micro X-ray computed tomography. Next, grain structure, crystallographic texture, and regions of recrystallization in the studied microstructures are measured using electron backscattered diffraction (EBSD). Lastly, chemistry, distribution, and morphological features of carbide phases are extracted using electron microscopy and X-ray diffraction. Strength in tension and compression are measured at room temperature for different initial microstructures created by variations in manufacturing conditions and sample orientations with respect to sample processing frame. While the strength of the alloy varies with sample orientation by approximately 30% in the as-built condition, the alloy is softer, more ductile, and approximately isotropic after HT. These results are discussed and critically compared with the data reported for the as-cast material. The alloy manufactured via LPBF is found to be significantly stronger and more ductile than the same alloy produced by casting. The interesting deformation behavior characteristics of the samples in different conditions are explained in terms of their microstructures. EBSD measurements reveal evolution from columnar grains along the build direction favoring a moderately strong <001> fiber texture in the as-built material to equiaxed grains favoring the {110}<001> Goss texture component after subsequent HTs. The major change in grain structure and texture is a result of recrystallization. While carbide phases precipitate primarily at dendrite and cellular interfaces in the as-built material, these phases are both intra-and inter-granular within the HT materials and coarsen with HT duration. These microstructural observations formed bases to rationalize the observed mechanical behavior of the alloy. With this being said, tailoring the alloy performance characteristics with HTs is reported on.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Neutron Absorber Plate Characterization Plan for Criticality Experiments Design

After being used in nuclear installations, depleted fuel can still be highly reactive and must be handled securely to prevent any radiological or criticality concerns. In particular, spent fuel from use in nuclear power reactors must be stored and transported in specifically designed containers using neutron absorber materials to prevent criticality. Various neutron absorber material types exist and are manufactured by various entities, as thoroughly described in the Handbook of Neutron Absorber Materials for Spent Nuclear Fuel Storage and Transportation Applications written by EPRI. Presently, one of the most modern and most widely used types of neutron absorber material contains particles of boron carbide, or B 4 C, embedded in aluminum matrix: Boralcan, manufactured by Rio Tinto. It is very important for the community to know as much as possible about such neutron absorber materials. Therefore, in the recent years, a US Department of Energy National Nuclear Security Administration–Nuclear Criticality Safety Program funded project initiated design of an experiment that places Boralcan neutron-absorbing plates in an established critical assembly using low-enriched uranium fuel at the Sandia Pulsed Reactor Facility/Critical Experiments (SPRF/CX) apparatus at Sandia National Laboratories. The goal of the experiment is to produce high-quality benchmark data to submit to the International Criticality Safety Benchmark Evaluation Project (ICSBEP), for use in validating calculational tools and nuclear data by criticality safety analysts. The project, named IER-554, is currently in its final design stage, following a successful preliminary design. In the work documented in the design study, ten critical configurations using Boralcan neutron absorber plates were designed, and the experiment was proven to be feasible, with a predicted low k eff uncertainty around 100 pcm. An overview of the modeled cutout of the critical assembly with a Boralcan plate is shown in Figure 1, representing one of the configurations planned for the critical experiments. Before the plates are inserted in the critical assembly, it is necessary to know more about their composition and uniformity. This summary focuses on the plate characterization plans. Each plate will undergo (1) neutron transmission measurements at different locations to determine the 10 B areal density and (2) an in-depth x-ray computed tomography (XCT) examination to obtain the exact Sizes and distribution of the B4C powder particles inside the plates. In parallel, plate modeling studies are performed with a goal to determine the validity of the currently used approximation of modeling the neutron absorber plates as a homogeneous mixture of Aluminum 1100 alloy and B4C— instead of explicitly modeling the B4C particles. By using the experimental 10 B areal density measurements, and the exact size and location of the B4C particles obtained by XCT, a plate model can theoretically be built that reproduces the plate with extremely high fidelity. The results of this modeling study could increase the confidence of the criticality safety community in its modeling methods when using this type of neutron absorber material, and the industry could use these validations to change the boron loading credit limits from the U.S. Nuclear Regulatory Commission standard review plan for dry cask storage of spent nuclear fuel. The modeling calculations are performed with SCALE 6.3.0 using the KENO V.a sequence for criticality calculations with the ENDF/B-VIII.0 continuous-energy cross section library.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2015

Plasma column and nano-powder generation from solid titanium by localized microwaves in air

This paper studies the effect of a plasma column ejected from solid titanium by localized microwaves in an ambient air atmosphere. Nanoparticles of titanium dioxide (titania) are found to be directly synthesized in this plasma column maintained by the microwave energy in the cavity. The process is initiated by a hotspot induced by localized microwaves, which melts the titanium substrate locally. The molten hotspot emits ionized titanium vapors continuously into the stable plasma column, which may last for more than a minute duration. The characterization of the dusty plasma obtained is performed in-situ by small-angle X-ray scattering (SAXS), optical spectroscopy, and microwave reflection analyses. The deposited titania nanoparticles are structurally and morphologically analyzed by ex-situ optical and scanning-electron microscope observations, and also by X-ray diffraction. Using the Boltzmann plot method combined with the SAXS results, the electron temperature and density in the dusty plasma are estimated as ∼0.4 eV and ∼10{sup 19 }m{sup −3}, respectively. The analysis of the plasma product reveals nanoparticles of titania in crystalline phases of anatase, brookite, and rutile. These are spatially arranged in various spherical, cubic, lamellar, and network forms. Several applications are considered for this process of titania nano-powder production.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2017

Microstructure evolution and dynamic recrystallization behavior of a powder metallurgy Ti-22Al-25Nb alloy during hot compression

The flow behavior of a powder metallurgy (P/M) Ti-22Al-25Nb alloy during hot compression tests has been investigated at a strain rate of 0.01 s{sup −1} and a temperature range of 980–1100 °C up to various true strains from 0.1 to 0.9. The effects of deformation temperature and strain on microstructure characterization and nucleation mechanisms of dynamic recrystallization (DRX) were assessed by means of Optical microscope (OM), electron backscatter diffraction (EBSD) and transmission electron microscope (TEM) techniques, respectively. The results indicated that the process of DRX was promoted by increasing deformation temperature and strain. By regression analysis, a power exponent relationship between peak stresses and sizes of stable DRX grains was developed. In addition, it is suggested that the discontinuous dynamic recrystallization (DDRX) and continuous dynamic recrystallization (CDRX) controlled nucleation mechanisms for DRX grains operated simultaneously during the whole hot process, and which played the leading role varied with hot process parameters of temperature and strain. It was further demonstrated that the CDRX featured by progressive subgrain rotation was weakened by elevating deformation temperatures. - Highlights: •Flow behavior of a P/M Ti-22Al-25Nb is studied by hot compression tests. •Microstructure evolution of alloy is affected by deformation temperature and strain. •The relationship between peak stress and stable DRX grain size was developed. •The process of DRX was promoted by increasing deformation temperature and strain. •Nucleation mechanisms of DRX were identified by EBSD analysis and TEM observation.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Synthesis and Magnetic Properties of Soft Magnetic Composites Based on Silicone Resin-Coated Iron Powders

Iron-based soft magnetic composites with silicone resin coating have been designed to reduce the core loss and improve the magnetic properties of cores. The silicone resin serving as electrical insulating layer was modified by 3-glycidoxypropyltrimethoxy silane, and the effect of silicone resin content, coupling agent, annealing treatment, and thermal cycling on the magnetic properties of composites was investigated in the frequency range from DC to 150 kHz. The coated silicone resin insulating layer was characterized by scanning electron microscopy and energy dispersive spectroscopy. The results showed that the optimum coating content of silicone resin to attain the acceptable permeability and the minimum magnetic loss for the prepared composites is 4 wt%. The sample with silicone resin coat exhibited better DC-bias superposition characteristics compared to the uncoated sample, 6 wt% silicone resin coating sample have excellent percentage effective permeability (84.8%) under 50 Oe applied field. AC magnetic properties evaluated at 1 and 100 kHz do not vary with a 95% confidence interval with the number of thermal cycles; therefore, the properties of the silicone resin-insulating composites are stable under thermal cycling.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2015

Experimental and theoretical characterization of ordered MAX phases Mo{sub 2}TiAlC{sub 2} and Mo{sub 2}Ti{sub 2}AlC{sub 3}

Herein, we report on the phase stabilities and crystal structures of two newly discovered ordered, quaternary MAX phases—Mo{sub 2}TiAlC{sub 2} and Mo{sub 2}Ti{sub 2}AlC{sub 3}—synthesized by mixing and heating different elemental powder mixtures of mMo:(3-m)Ti:1.1Al:2C with 1.5 ≤ m ≤ 2.2 and 2Mo: 2Ti:1.1Al:2.7C to 1600 °C for 4 h under Ar flow. In general, for m ≥ 2 an ordered 312 phase, (Mo{sub 2}Ti)AlC{sub 2}, was the majority phase; for m < 2, an ordered 413 phase (Mo{sub 2}Ti{sub 2})AlC{sub 3}, was the major product. The actual chemistries determined from X-ray photoelectron spectroscopy (XPS) are Mo{sub 2}TiAlC{sub 1.7} and Mo{sub 2}Ti{sub 1.9}Al{sub 0.9}C{sub 2.5}, respectively. High resolution scanning transmission microscopy, XPS and Rietveld analysis of powder X-ray diffraction confirmed the general ordered stacking sequence to be Mo-Ti-Mo-Al-Mo-Ti-Mo for Mo{sub 2}TiAlC{sub 2} and Mo-Ti-Ti-Mo-Al-Mo-Ti-Ti-Mo for Mo{sub 2}Ti{sub 2}AlC{sub 3}, with the carbon atoms occupying the octahedral sites between the transition metal layers. Consistent with the experimental results, the theoretical calculations clearly show that M layer ordering is mostly driven by the high penalty paid in energy by having the Mo atoms surrounded by C in a face-centered configuration, i.e., in the center of the M{sub n+1}X{sub n} blocks. At 331 GPa and 367 GPa, respectively, the Young's moduli of the ordered Mo{sub 2}TiAlC{sub 2} and Mo{sub 2}Ti{sub 2}AlC{sub 3} are predicted to be higher than those calculated for their ternary end members. Like most other MAX phases, because of the high density of states at the Fermi level, the resistivity measurement over 300 to 10 K for both phases showed metallic behavior.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Selective conversion of methane to aromatic hydrocarbons on large crystallite zeolite catalysts with mesoporous structure

Large crystallite mesoporous MFI (ZSM-5) zeolite was synthesized by using carbon nano-powder as a secondary template. The surface properties, morphological and phase composition of the synthesized material and of the commercial ZSM-5 (Zeolyst) zeolite were studied by nitrogen porosimetry, XRD and scanning electron microscopy. The results showed that the volume of mesopores volume increases with development of a secondary mesoporosity in the structure of zeolite. The obtained zeolite supports were used to prepare molybdenum-containing catalysts for the methane aromatization by solid phase preparation technique. Based on the XPS data, molybdenum particles in these catalysts are characterized by more uniform size distribution. The formation of a secondary pore structure restrains the carbon deposit formation as well as increases the methane conversion and the yield of the aromatic compounds.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2015

High-strength bioresorbable Fe–Ag nanocomposite scaffolds: Processing and properties

High strength ductile iron-silver nanocomposite scaffolds were fabricated employing high energy attrition milling of micron-submicron powders, followed by cold sintering/high pressure consolidation. Particulate leaching method with soluble Na{sub 2}SO{sub 4} and K{sub 2}CO{sub 3} salts as porogens was used to create scaffolds with 50, 55, 60 and 73% volume fraction of pores. Part of specimens was annealed at 600, 800 and 900°C. Specimens were characterized employing X-ray diffraction, scanning electron microscopy (SEM) with electron probe microanalysis (EDS) and high resolution SEM. Mechanical properties were measured in compression and permeability was measured in permeameter based on Darcy’s law. Scaffolds with 50% and 55% porosity exhibited high compressive strength (18–22 MPa), compressive strength of 8–12 MPa was observed for scaffolds with 73% porosity. Treatments at 800 and 900°C result in increase of strength and ductility with some coarsening of microstructure. Best combination of compressive strength (15 MPa) and permeability (0.6{sup −6} cm{sup 2}) is close to the range of trabecular bone.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Multi phenomena melt pool sensor data fusion for enhanced process monitoring of laser powder bed fusion additive manufacturing

Finding actionable trends in laser-based metal additive manufacturing process monitoring data is challenging owing to the diversity and complexity of the underlying physical interactions. A single monitoring solution that captures a particular process phenomenon, such as a photodiode that tracks melt pool intensity, is not alone capable of evaluating process stability or detecting flaw formation with sufficient precision for routine application in industry. In this work, to improve flaw detection performance, we adopted a data fusion approach that captures multiple process phenomena. To demonstrate this, we acquired data from laser powder bed fusion (LPBF) builds of cylindrical specimens produced with different laser spot sizes, emulating defocusing due to process faults such as thermal lensing. The resulting specimens had porosity of varying types and severity, quantified by post-build non-destructive X-ray computed tomography, Archimedes density measurements, and destructive metallographic characterization. During the build, the melt pool state was monitored with two coaxial high-speed video cameras and a temperature field imaging system. Physically intuitive low-level melt pool signatures, such as melt pool temperature, shape and size, and spatter intensity were extracted from this high-dimensional, image-based sensor data. These process signatures were subsequently used as input features in relatively simple machine learning models, such as a support vector machine, which were trained to detect laser defocusing, and in addition, predict porosity type and severity. The results show that the data fusion approach significantly enhanced system performance by reducing the overall false positive rate from ~ 0.1 to ~ 0.001 without sacrificing the true positive rate (~0.90). These results were at par with a black-box, deep machine learning approach (convolutional neural network).

36 MATERIALS SCIENCE↗
DOE OSTI2024

Reactive flash sintering and characterization of bulk high entropy nitrides

Over the past decade, numerous high-entropy ceramics have been synthesized, often displaying attractive properties. However, the study on facile preparation of bulk high entropy nitrides (HEN) are limited, despite its broad potential applications. This research demonstrates for the first time rapid fabrication (within ∼6 min) of bulk high-entropy nitrides, especially (Al 0.17 Nb 0.17 Ta 0.17 Ti 0.32 Zr 0.17 )N, from binary nitride powder mixtures using a highly efficient reactive flash sintering (RFS) technique. X-ray diffraction (XRD) shows the HENs from RFS are near single-phase solid solutions with a rock salt crystal structure, while in situ synchrotron study carried out during RFS captured in real time the formation of HEN, which was preserved upon cooling, suggesting thermodynamic stability of the HEN phase, even up to extreme pressure (∼35.6 GPa). Microscopic analyses using SEM, STEM, and EDS reveal decent uniformity for HEN with no obvious segregation of elements, even to submicron scale. Some properties of the obtained bulk HENs are consistent with expectations. For example, their hardness and bulk modulus are close to estimates based on rule-of-mixture (ROM) values from the constituent binary nitrides. Meanwhile, some other measured properties seem to show surprises. For example, the fracture toughness for the HENs (e.g., 7.81 ± 1.40 MPa•m 1/2 or higher) turns out to be more than double of the expected ROM estimates. The significantly improved fracture toughness is attributed to the observed nano-layered structure of the HENs, despite the HEN’s cubic crystal structure and high hardness. In addition, the oxidation resistance shows improvement up till ∼800°C, possibly due to Ta doping that suppress oxygen vacancy formation in the oxide shell, while the 5-metal HEN of (Al 0.17 Nb 0.17 Ta 0.17 Ti 0.32 Zr 0.17 )N displays superconductivity (T c of ∼5–7 K from magnetism and resistivity measurements, slightly lower than ROM estimate), despite insulating property of starting AlN. Furthermore, future study combining experimental investigation using larger samples to confirm the observed increase in fracture toughness and oxidation resistance, theoretical modeling at different length scale, and more detailed structural/chemical characterization, especially at the atomic scale, are all needed to fully understand the inter-relationships between composition, processing, structure, and novel properties for these HENs and the development of related new materials for different applications.

Flash sintering↗
DOE OSTI2017

Characterization of Crystallographic Structures Using Bragg-Edge Neutron Imaging at the Spallation Neutron Source

Over the past decade, wavelength-dependent neutron radiography, also known as Bragg-edge imaging, has been employed as a non-destructive bulk characterization method due to its sensitivity to coherent elastic neutron scattering that is associated with crystalline structures. Several analysis approaches have been developed to quantitatively determine crystalline orientation, lattice strain, and phase distribution. In this study, we report a systematic investigation of the crystal structures of metallic materials (such as selected textureless powder samples and additively manufactured (AM) Inconel 718 samples), using Bragg-edge imaging at the Oak Ridge National Laboratory (ORNL) Spallation Neutron Source (SNS). Firstly, we have implemented a phenomenological Gaussian-based fitting in a Python-based computer called iBeatles. Secondly, we have developed a model-based approach to analyze Bragg-edge transmission spectra, which allows quantitative determination of the crystallographic attributes. Moreover, neutron diffraction measurements were carried out to validate the Bragg-edge analytical methods. These results demonstrate that the microstructural complexity (in this case, texture) plays a key role in determining the crystallographic parameters (lattice constant or interplanar spacing), which implies that the Bragg-edge image analysis methods must be carefully selected based on the material structures.

47 OTHER INSTRUMENTATION↗
DOE OSTI2021

Pulsed electric current joining of oxide-dispersion-strengthened austenitic steels

The solid-state joining of oxide-dispersion-strengthened (ODS) austenitic steels was achieved using a pulsed electric current joining (PECJ) process. Microstructures of the austenitic grain structures and oxide dispersions in the joint areas were characterized using electron microscopy. Negligible grain growth was observed in austenitic grain structures, while slight coarsening of oxide dispersions occurred at a short holding time. The mechanisms of the PECJ process may involve three steps that occur simultaneously, including the sintering of mechanical alloying powders in the bonding layer, formation of oxide dispersions, and bonding of the mechanical alloying powders with the base alloy. The high hardness and irradiation resistance of ODS alloys were retained in the joint areas. This research revealed the fundamental mechanisms during the PECJ process, which is beneficial for its potential applications during the advanced manufacturing of ODS alloys.

36 MATERIALS SCIENCE↗