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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Precipitate Characterization in Model Al-Zn-Mg-(Cu) Alloys Using Small-Angle X-ray Scattering

Model 7000 series alloys with and without copper were fabricated into sheets to study precipitation hardening behavior under isothermal aging conditions. Samples of each alloy were subjected to 3 h annealing treatments at various temperatures to produce a range of precipitate size distributions. Hardness, electrical conductivity, and small-angle X-ray scattering (SAXS) were used to characterize the aging behavior of the two alloys. Precipitate size distributions were modeled from the scattering curves for each annealing condition using a maximum entropy method (MEM) and compared to select transmission electron microscopy (TEM) results. The measured average precipitate diameters from TEM were in good agreement with the average precipitate diameters determined from the scattering curves.

36 MATERIALS SCIENCE↗
NASA NTRS1966

Use of steel and tantalum apparatus for molten Cd-Mg-Zn alloys

Steel and tantalum apparatus contains various ternary alloys of cadmium, zinc, and magnesium used in pyrochemical processes for the recovery of uranium-base reactor fuels. These materials exhibit good corrosion resistance at the high temperatures necessary for fuel separation in liquid metal-molten salt solvents.

Bennett, G. A.↗
NASA NTRS1991

Microstructure-property relationships in Al-Cu-Li-Ag-Mg Weldalite (tm) alloys, part 2

The microstructure and mechanical properties of the ultrahigh strength Al-Cu-Li-Ag-Mg alloy, Weldalite (tm) 049, were studied. Specifically, the microstructural features along with tensile strength, weldability, Young's modulus and fracture toughness were studied for Weldalite (tm) 049 type alloys with Li contents ranging from 1.3 to 1.9 wt. pct. The tensile properties of Weldalite 049 and Weldalite 049 reinforced with TiB2 particles fabricated using the XD (tm) process were also evaluated at cryogenic, room, and elevated temperatures. In addition, an experimental alloy, similar in composition to Weldalite 049 but without the Ag+Mg, was fabricated. The microstructure of this alloy was compared with that of Weldalite 049 in the T6 condition to assess the effect of Ag+Mg on nucleation of strengthening phases in the absence of cold work.

Langan, T. J.↗
DOE OSTI2022

Investigation of twin growth mechanisms in precipitate hardened AZ91

Here, in this work, an elasto-viscoplastic fast-Fourier-transform (EVP-FFT) model with a dislocation-density (DD) based hardening law is employed to study the growth of a {10$\bar{1}$2} tensile twin that is blocked by basal-precipitates in precipitate-hardened AZ91 magnesium alloy. It is frequently reported that twin growth is hindered in precipitate-hardened Mg alloys; however, thick twin domains are often observed experimentally in these material systems. Detailed numerical investigation of deformation twinning starting from an early propagation stage, before twin growth, reveals that the stress fields that result from two sequentially propagated twins co-impinging on a precipitate relaxes the twin back stress locally and promotes twin growth at the twin-precipitate junction. Based on these findings, a two-step growth mechanism is proposed for twins arrested by precipitates. In the first step, the interaction of a twin tip with a precipitate develops a stress concentration on the other side of the precipitate, prompting the formation of a second twin. Subsequently, the back stresses associated with the first twin are relaxed by the formation of the second twin, allowing the first twin to grow at the twin-precipitate junction and eventually engulf the precipitate. This mechanism suggests that twin growth can be achieved locally with minimal additional external forces, explaining how relatively large twin domains can develop even in the presence of arrays of precipitates.

36 MATERIALS SCIENCE↗
NASA NTRS1991

Evaluation of the microstructure of Al-Cu-Li-Ag-Mg Weldalite (tm) alloys, part 4

Weldalite (trademark) 049 is an Al-Cu-Li-Ag-Mg alloy designed to have ultrahigh strength and to serve in aerospace applications. The alloy displays significantly higher strength than competitive alloys in both naturally aged and artificially aged tempers. The strengthening phases in such tempers have been identified to, in part, explain the mechanical properties attained. In general, the alloy is strengthened by delta prime Al3Li and Guinier-Preston (GP) zones in the naturally aged tempers. In artificially aged tempers in slightly underaged conditions, strengthening is provided by several phases including GP zones, theta prime Al2Cu, S prime Al2CuMg, T(sub 1) Al2CuLi, and possibly a new phase. In the peak strength artificially aged tempers, T(sub 1) is the predominant strengthening phase.

Pickens, Joseph R.↗
DOE OSTI2023

Atmospheric Pressure Plasma Treatment of Magnesium Alloy for Enhanced Coating Adhesion and Corrosion Resistance

Atmospheric pressure plasma (AP) treatment, using an open-air jet of ionized CO 2 , N 2 , or air, was applied to AZ91D Mg alloy surfaces to investigate its effects on primer coating adhesion and corrosion resistance. The CO 2 and air AP treatments formed an O- and C-rich surface layer (Mg-O-C) consisting of agglomerated nanoparticles and pits with a depth of a few microns and increasing the surface roughness by 6–8 times compared with the reference 600 grit-finished surface. Then, three commercial primers, zinc phosphate (ZnP), chromate-containing epoxy, and MIL23377, were applied on the treated surfaces to evaluate the corrosion resistance associated with the coating adhesion. Microscopic analysis demonstrated stronger interlocking between the primer layer and the nano-/microrough Mg-O-C surface compared to the untreated (600 grit-finished) surfaces, indicating improved coating adhesion and corrosion resistance. Crosscut tests of the MIL23377 primer on the CO 2 and air AP-treated surfaces showed the highest level of adhesion, ASTM class 5B. Salt spray corrosion tests showed that after 8 days of exposure, the primer coatings on air AP-treated surfaces had corrosion areas that were more than four times smaller than that of the 600 grit-finished surface. The N 2 AP treatment showed similar adhesion enhancement. The preliminary operation expenses for AP treatment using CO 2 , N 2 , and air were estimated at USD 30.62, USD 35.45, and USD 29.75 (from an air cylinder)/USD 0.66 (from an air compressor) per m 2 , respectively.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Report on use of Inoculants in Missile Application Alloys

This report documents the status of current inoculant research relevant to missile application alloys and MTCR control language. The information is intended to provide data on current inoculants for us determining the current state of development and identifying potential research directions. Although there has been significant scientific research into the development and synthesis of inoculants, their current availability is limited is traditional powder inoculants employed during casting processes. However, research continues the development of complex oxides, ribbon materials, high entropy alloys, and other inoculant product forms, including the use of inoculants in the melt pools produced during additive manufacturing. Research to date has focused primarily on aluminum and steel alloys with emphasis on refining grain structures and evolving equiaxed morphologies while increasing strength and castability. The primary inoculants in steel and cast irons include TiN, SiC, FeSi75, and Ce which have increased strength properties. Chief inoculants for Al alloys often include TiC, SiC, Al3Sc(x) and TiB2 to aid in precipitation and refinement. Ti and Ni alloys have fewer research activities involving inoculants, although TiN, TiB, ZrN and LaB6 (for Ti alloys) and WC, Co3FeNb2, and CrFeNb (for Ni alloys) have been used. Sic, Al2O3, Mg and Ti are key inoculants for Mg alloys. Multiple cast alloys from each of the material classes demonstrated increased strength and performance properties using inoculants, with several approaching requirements applicable to missile service environments. The continued evolution of advanced manufacturing capabilities is making it easier to produce high temperature near net shape structural materials using inoculant powders. These shapes may include the geometric shapes addressed within the MTCR (tubes and limited wall thicknesses). The use of inoculants may enable further development of high temperature alloys into near net shapes traditionally produced via casting processes due to limited ductility. This may decrease material and manufacturing costs. In addition, inoculation provides controlled kinetics and achievable chemical segregation that enables potential for far-from equilibrium thermodynamic microstructures and chemistries that could provide new metastable alloy states and subsequent properties to address co-design engineering constraints, including needs for increased strength and ductility. It is recommended that specific material combinations within these alloy classes be carefully watched as the materials evolve, with controls aimed at those having material properties above current MTCR levels. This specifically includes the use of refractory inoculants in alloys, and the application of inoculants in high strength and high temperature alloys via additive manufacturing processes, with care to link capabilities to product forms similar to the current requirements on tube geometries and material feed stocks. The continued development of nanoparticle inoculants will increase strength and ductility of high strength castings and additive manufactured metallic components. For example, adding inoculants into the casting of maraging steels and other precipitation strengthened alloys may drastically elevate mechanical properties above the control limit of current regulations.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Solutes that reduce yield strength anisotropies in magnesium from first principles

Using Labusch-type solid solution strengthening models parameterized with DFT-computed solute-dislocation interaction energies, we perform a computational search for 63 solutes across the periodic table to find those that lower anisotropy ratios (non-basal to basal CRSS) of magnesium potentially increasing its ductility per the von Mises criterion. For this purpose, we compute changes in strength for solutes as a function of composition and temperature, and compute anisotropy ratios for solutes that include both rare earth and non-rare earth elements. Here we specifically focus on solute-dislocation interaction energies in the following DFT-optimized dislocations as representative of three non-basal plastic deformation modes: $\langle c + a \rangle$ edge, (10$\bar1$2) tension twinning edge, and the (10$\bar{1}$1) compression twinning edge. We find that solute-induced changes in non-basal deformation modes can be approximated using a second-order polynomial in the size misfit of the solutes, which permits rapid screening of solutes. Our approach to identify solutes known to improve strengthening incorporates solute solubility, and suggests other solutes that not have been previously explored for strengthening. The 8 rare-earth solutes that our method suggests as the best, ordered by increasing anisotropy ratios at their optimal concentrations, are: Gd, Tb, Dy, Nd, Ho, Er, Tm, and Yb. The 12 non-rare-earth solutes that our method suggests as the best, ordered by increasing anisotropy ratios, are: Y, Mn, Sc, Pb, Ca, Ag, Bi, Tl, Zn, Li, Ga, and Al. Of these, Gd, Nd, Er, Yb, Y, Mn, Ca, Zn, Li, and Al are used in commercial Mg alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Three-dimensional microstructure of a friction stir welded magnesium/steel interface characterized via high-energy synchrotron X-rays

Here, the three-dimensional (3D) microstructure of a friction stir assisted scribe technique (FaST) weld interface consisting of AZ31 magnesium (Mg) alloy and zinc (Zn)-coated DP590 steel was analyzed via synchrotron micro-computed tomography (μ-CT), correlated to synchrotron x-ray diffraction, and electron microscopy. Diffraction assessment of the AZ31/Zn-coated DP590 steel interface revealed the presence of several complex Mg–Zn intermetallic phases and differences in crystalline orientation of the Mg phase at the weld interface. The 3D characterization of the synchrotron μ-CT images of the weld interface revealed: (1) the presence of AZ31 weld nugget material with iron (Fe)-rich particles; (2) the presence of a weld layer at the joining interface with Fe-rich particles; (3) the formation of a thin non-uniform layer between the weld layer and the interface of the scribed DP590 material; and (4) the presence of an Fe–Al-rich intermetallic layer and Fe-rich particles at the interface of the scribed DP590 material. This study also performed a detailed analysis of lump-like features seen in the Zn coating layer at the weld interface. A detailed 3D particle analysis of the Fe-rich particles in the AZ31 weld nugget and the weld layer at the weld interface revealed the presence of several types of particle morphologies (i.e., spherical and irregular).

36 MATERIALS SCIENCE↗
DOE OSTI2023

Microstructural, Corrosion and Mechanical Characterization of Friction-Stir Welded Joints Between Aluminum and Magnesium Alloys

Friction Stir Welding (FSW) of Aluminum-Magnesium (Al-Mg) alloys has garnered increasing attention due to its wide-ranging applications in the automotive and aerospace industries. The microstructural, corrosion, and mechanical properties of FSW Al-Mg welds under selected conditions are critical factors that must be well-investigated to ensure their durability and performance. In this study, electrochemical tests, including Open Circuit Potential (OCP), Linear Polarization Resistance (LPR), Potentiodynamic Polarization Scan (PD), and Electrochemical Impedance Spectroscopy (EIS), have been used to analyze the corrosion resistance of these welds, along with weight loss measurements through cyclic corrosion testing (CCT) and surface evolution via SEM over an 8-week period. Mechanical properties are evaluated through microindentation, nanoindentation, fatigue, and lap-shear tests. The results of the electrochemical tests reveal that the corrosion properties of the center weld zone differ from those of the two base alloys. Indentation tests indicate that the weld zone behaves differently from the base alloys. Surprisingly, the lap shear strength did not decrease significantly even after 8 weeks of cyclic corrosion testing, indicating that the joint prevented any ingress of the electrolyte. Fatigue testing showed that applying an adhesive between the Al and Mg joint improved the fatigue life to some extent, although the corrosion resistance reduced due to the discontinuous bonding of the adhesive layer. Overall, these findings highlight the importance of investigating the corrosion and mechanical properties of FSW Al-Mg welds and provide valuable insights for future modeling works.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗