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At least 127 records · Page 7

Intentional Uranium Tagging for Material Provenance and Pathway Forensics (LA19-Intentional-Forensics-NDD3Bb) (Annual Report for FY21)

This report describes the outcomes of the third and final year of a project to research the feasibility of tagging uranium materials, especially nuclear fuels. The experimental focus remained on metallic uranium forms under prospective surface and bulk tagging scenarios. Overall, the results showed that the tags could be successfully imparted and characterized in both as-built and degraded conditions. This was in line with expectations coming into this project, indicating promise for both surface and bulk tagging of metallic forms of uranium. Multiple surface tagging techniques and detection strategies were explored in FY21, with an emphasis on improving tag quality, readability, and detection in the field. Non-radioactive materials were used as a testbed. Selective deposition via laser beam was determined to be successful in imparting a readable titanium deposit on a stainless steel base plate, and can be read with high resolution characterization techniques (e.g., scanning electron microscopy) and field capable tools (e.g., eddy current testing). Other deposition techniques, such as selective deposition via electron beam and photoluminescent tags, were explored in FY21, and while success for these techniques would be dependent on additional work, these techniques showed potential for surface tagging applications. To survey bulk taggant elements for bulk uranium metal, 16 tagging elements were spread among 18 depleted uranium castings (4 baseline, 3 mix, 1 dilution, and 10 recycle). Most of these were made and characterized in FY21. Taggant acceptability was based upon manufacturability, detectability, and persistence from the standpoint of two detection options: bulk chemical analysis (for “chemical taggants”) and microstructural analysis (for “second phase taggants”). Taggant detection in both up-front manufacturing and in the face of “degradations” such as dilution, mixing, and recycling was generally good. Two independent laboratories carried out chemical analysis on most of the castings, and often at several locations within a casting, and the results are discussed. Scanning electron microscopy+EDS microanalysis revealed the second phases mostly contained the expected tagging elements. The shapes and 2 spatial distributions of these micron-sized carbides, oxides, and intermetallic particles offers opportunities for further science-based investigation and tagging optimization. Overall, V and Co currently appear as the best choices for chemical taggants while Al, Ti, Mn, Co, Pd, and Tb all look good as second phase taggants. The other elements considered here – Sc, Ni, Ge, Nb, Ce, Ta, W, Ir, and Au – while not being ruled out, require more study to become viable options. It is of special note that in the recycling study only one of the 12 elements fell out of detection even after 10 meltings, demonstrating their persistence. An Appendix tabulates all chemical analysis results to enable more quantitative and statistical studies of detection opportunities and limitations, as a part of a related project.

36 MATERIALS SCIENCE↗

Adaptive Forward Modeling Method for Analysis and Reconstructions of Orientation Image Map

IceNine is a MPI-parallel orientation reconstruction and microstructure analysis code. It's primary purpose is to reconstruct a spatially resolved orientation map given a set of diffraction images from a high energy x-ray diffraction microscopy (HEDM) experiment (1). In particular, IceNine implements the adaptive version of the forward modeling method (2, 3). Part of IceNine is a library used to for conbined analysis of the microstructure with the experimentally measured diffraction signal. The libraries is also designed for tapid prototyping of new reconstruction and analysis algorithms. IceNine is also built with a simulator of diffraction images with an input microstructure.

Frankie Li, ShiuFai↗

Adaptive Forward Modeling Method for Analysis and Reconstructions of Orientation Image Map

IceNine is a MPI-parallel orientation reconstruction and microstructure analysis code. It's primary purpose is to reconstruct a spatially resolved orientation map given a set of diffraction images from a high energy x-ray diffraction microscopy (HEDM) experiment (1). In particular, IceNine implements the adaptive version of the forward modeling method (2, 3). Part of IceNine is a library used to for conbined analysis of the microstructure with the experimentally measured diffraction signal. The libraries is also designed for tapid prototyping of new reconstruction and analysis algorithms. IceNine is also built with a simulator of diffraction images with an input microstructure.

Frankie Li, Shiu Fai↗

Impact of microstructure on the thermoelectric properties of the ternary compound Ce{sub 3}Cu{sub 3}Sb{sub 4}

We present detailed structural and thermoelectric studies of the ternary compound Ce{sub 3}Cu{sub 3}Sb{sub 4}. This material is of interest due to previously reported considerable thermopower above room temperature (∼ 100 μV/K) and low thermal conductivity (2 W/(m K)). Here, we present detailed studies concerning microstructural and thermoelectric data, their variation across the samples and possible explanations for the observed behaviour. We have used X-ray diffraction, scanning electron microscopy (SEM), and time-of-flight secondary ion mass spectrometry (TOF-SIMS) for microstructural analysis. The thermoelectric properties were examined using a physical property measurement system (PPMS). We analyse the impact of the sample quality on the thermoelectric properties. The most unstable parameter is the material resistivity which varies between 1.5 and 15 mΩ cm at room temperature. The properties variability is mainly due to structural defects caused by stresses during material preparation and also due to formation of foreign phases CeCuSb{sub 2} and CeSb. The figure of merit ZT is also strongly dependent on the quality of the sample. The largest value ZT ≈ 0.15 at 400 K is determined for the almost stoichiometric sample with small amounts of a impurity phases. - Highlights: •The Ce{sub 3}Cu{sub 3}Sb{sub 4} has considerable thermoelectric properties and potential for further chemical and/or structural modification. •The control over foreign phases formation is challenging. •The defects arising during arc melting process highly deteriorate ZT of material.

36 MATERIALS SCIENCE↗

Fabrication and characterization of a novel β metastable Ti-Mo-Zr alloy with large ductility and improved yield strength

Highlights: • Ti-12Mo-5Zr alloy exhibits excellent combination of improved yielding strength (>650 MPa), high ductility (uniform elongation ≈30%) and work-hardening behaviour. • The superior performances arise from the synergic effects between phase transformation induced plasticity and twinning induced plasticity. • The ‘d-electron’ alloy design approach in Ti-12Mo-5Zr alloy, i.e. Zr substitution to Ti, validates the feasibility of yielding stress improvement of TWIP/TRIP titanium alloys. - Abstract: In this paper, a novel ternary β-metastable titanium alloy, Ti-12Mo-5Zr (wt%), was designed based on the “d-electron” alloy design theory. The Ti-12Mo-5Zr alloy displays excellent combination of improved yielding stress (>650 MPa), high ductility (uniform elongation ≈30%) and work-hardening behaviour. The detailed microstructural analysis indicates that the superior performances arise from the synergic effects between phase transformation induced plasticity (TRIP) and twinning induced plasticity (TWIP). Conforming to the design strategy, the improvement of mechanical performance results from the addition of Zr alloying element in substituting Ti, attributing to solution hardening effect and the increasing of critical resolved shear stress (CRSS) of stress induced martensitic transformation (SIM α″).

36 MATERIALS SCIENCE↗

In-Situ Synchrotron and Neutron Radiation at International User Facilities Take Welding Research to a New Level

Over the past century the principal method for understanding the effects of welding on the mechanical and physical integrity of the final joint has been post-weld microstructure analysis, and it’s the interpretation of these microstructures that sets welding metallurgy apart from other related scientific fields. In conjunction with heat flow analysis, thermodynamics, and kinetics, post-weld visual observations have provided the framework for interpreting the events that lead to the final weld microstructure. However, without direct and confirming evidence of the actual phases that exist during welding, or measurement of invisible weld properties such as crystal structure and residual stress, multiple interpretations for microstructural evolution of welds are possible. For these reasons, new methods are being developed for the direct observation of phase transformations that occur both during and as a result of welding, using modern synchrotron and neutron user research facilities.

36 MATERIALS SCIENCE↗

In-situ investigation of incipient melting in a 319 type Al alloy using laser scanning confocal microscopy

Highlights: • In-situ analysis of incipient melting of ternary eutectic in Al alloy. • Incipient melting occurred in three distinct stages in the eutectic. • Increased heating rate increase rate of liquid film propagation. • Incipient melting transformed initial eutectic structure and caused oxidation. • Study determined incipient melting mechanism for eutectic structures. - Abstract: The modified 319 Al alloy system has been used extensively in precision sand casting of automotive powertrain applications such as engine blocks and cylinder heads, with significant improvement in vehicle fuel efficiency. However, a concern in elevated temperature processing of Al alloys, such as heat treatment and hot working processes, is incipient melting of secondary phases, which is deleterious to mechanical properties. In this study, the laser scanning confocal microscopy (LSCM) technique was used in the analysis of in-situ changes in microstructure as a result of incipient melting. Microstructural analysis was carried out prior to and following elevated temperature exposure in the LSCM using optical microscopy, SEM and EDX. The results suggest that incipient melting of the Al-Al{sub 2}Cu-Al{sub 5}Mg{sub 8}Cu{sub 2}Si{sub 6} ternary eutectic clusters was initiated by the formation of a liquid film which propagated rapidly from the eutectic clusters, coating the Al dendrites in regions adjacent to the eutectic clusters. Following film formation, the ternary eutectic clusters melted completely. Incipient melting also resulted in a localized change in composition in the interdendritic channels as supported by a change in cluster morphology from eutectic to a combination of coarse blocky Al-Cu-Ni and Si particles, and ultra-fine eutectic.

36 MATERIALS SCIENCE↗

Shear assisted processing and extrusion of enhanced strength aluminum alloy tubing

Hollow extrusions are used in many industries to make strong, lightweight, and affordable structures. Shear Assisted Processing and Extrusion (ShAPE) enables the extrusion of many alloys, often with noteworthy properties. In this investigation, ShAPE was used to extrude 1 and 2 mm wall tubes of aluminum alloy 6063 measuring 12 mm in diameter at extrusion speeds up to 3.8 m/min. This speed is 10 and 15 times faster than has been reported for any alloy using ShAPE and friction stir back extrusion, respectively. Increasing the extrusion speed from 0.7 to 3.8 m/s resulted in using 68% less process energy at steady state. Microstructural analysis and tensile testing were performed on as-extruded tubes and tubes with a direct T5 heat treatment. Grain refinement from 65 µm to below 20 µm was observed. Growth of macroscale Mg 2 Si strengthening precipitates was not observed. ShAPE processing resulted in recrystallization, and extrusion speed was shown to influence final extrudate texture. Here, transmission electron microscopy analysis revealed that the as-extruded microstructure was free of nanoscale ß" strengthening precipitates. Nanoscale ß" was prominent in direct-aged (T5) ShAPE tubes, similar to a slightly over-aged conventional T6 microstructure. As-extruded tubes had ultimate tensile strengths on par with conventional T5 extrusions and approximately double the total elongation. Tubes that underwent a T5 heat treatment had yield and ultimate strengths averaging 198 and 234 MPa, respectively, with an average total elongation of 11%. The tensile test results are comparable to a conventional T6 heat treatment, but without the solutionization heat treatment step. Mechanical properties either remained flat or improved with increased extrusion speed, which suggests that ShAPE can be scaled up to an industrial process to create energy- and economically efficient high-strength extrusions.

36 MATERIALS SCIENCE↗

Extrinsic mechanism for giant dielectric response in Ba{sub 0.70}Sr{sub 0.30}(Fe{sub 0.5}Nb{sub 0.5})O{sub 3} ceramic

To obtain the high dielectric constant, the effect of sintering process on the electrical properties of Ba{sub 0.70}Sr{sub 0.30}(Fe{sub 0.5}Nb{sub 0.5})O{sub 3} ceramics were investigated. X-ray diffraction pattern of the samples at room temperature shows a monoclinic structure. Microstructure analysis shows well-grown and dense microstructure in all the samples. We found giant dielectric constant (∼3.59 × 10{sup 5}) with low dielectric loss (∼0.49) at room temperature for 2 hr sintered sample at 1250 °C. The extrinsic phenomena like interfacial polarization due to space charge accumulation at grain boundaries are discussed.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

Notch-tensile behavior of Al0.1CrFeCoNi high entropy alloy

Notch-tensile behavior of an Al0.1CrFeCoNi high entropy alloy (Al0.1-HEA) was studied using V-notch geometry and with local strain mapping using digital image correlation (DIC). A notch-strength ratio of 1.51 indicated notch strengthening. Further analysis of stress-strain response supplemented with microstructural analysis revealed that, while the presence of notch results in strengthening due to work hardening by twinning induced plasticity, the notch also contributes strongly to geometrical softening in the non-uniform ductility regime, and accounts for the onset of failure. The strain localization behavior of Al0.1-HEA due to the presence of V-notch was compared with three conventional alloys: Inconel 625 nickel-based superalloy, 304 stainless steel and Ti–6Al–4V titanium alloy. The study revealed that the nature of notch widening with increasing strain was dependent on material characteristics. The extent of notch widening impacted the local strain field and stress distribution, thereby influencing the propensity for crack initiation and growth. The experimental results were verified by finite element analysis.

Sinha, Subhasis↗

Rietveld Refinement for Macromolecular Powder Diffraction

Powder X-ray diffraction (PXRD) has been employed extensively for the structural characterization of materials, quantitative analysis of multicomponent mixtures, phase identification, texture, and microstructural analysis. At the heart of all those lies the Rietveld method, which has revolutionized the use of powder diffraction for materials studies. Initially applied to minerals and inorganics, the Rietveld method has progressively been used for more complex materials, for instance, zeolites and pharmaceuticals. A major advance of the method came some 20 years ago, when the first protein structure was successfully refined. Because of the sheer complexity of macromolecules, several new approaches and algorithms had to be pioneered or adapted from macromolecular single-crystal diffraction experiments, thus constituting macromolecular PXRD a quite unique field of study. This review aims to provide necessary elements of theory and application of structure solution and refinement via the Rietveld method for macromolecular PXRD data. Here, practical explanations and highlighted case studies are also presented.

36 MATERIALS SCIENCE↗

Specific Adaptation of Gas Atomization Processing for Al-Based Alloy Powder for Additive Manufacturing

The initial three atomization attempts resulted in “freeze-outs” within the pour tubes in the pilot-scale system and yielded no powder. Re-evaluation of the alloy liquidus temperatures and melting characteristics, in collaboration with Alcoa, showed further superheat to be necessary to allow the liquid metal to flow through the pour tube to the atomization nozzle. A subsequent smaller run on the experimental atomization system verified these parameters and was successful, as were all successive runs on the larger pilot scale system. One alloy composition froze-out part way through the atomization on both pilot scale runs. SEM images showed needle formation and phase segregations within the microstructure. Analysis of the pour tube freeze-out microstructures showed that large needles formed within the pour tube during the atomization experiment, which eventually blocked the melt stream. Alcoa verified the needle formation in this alloy using theoretical modeling of phase solidification. Sufficient powder of this composition was still generated to allow powder characterization and additive manufacturing trials at Alcoa.

36 MATERIALS SCIENCE↗

Three dimensional microstructural characterization of nanoscale precipitates in AA7075-T651 by focused ion beam (FIB) tomography

The size and distribution of precipitates in Al 7075 alloys affects both the mechanical and corrosion behavior (including stress corrosion cracking and fatigue corrosion) of the alloy. Three dimensional (3D) quantitative microstructural analysis of Al 7075 in the peak aged condition (T651) allows for a better understanding of these behaviors. In this study, Focused ion beam (FIB) tomography was used to characterize the microstructure in three dimensions. Analysis of grains and precipitates was performed in terms of volume, size, and morphology. It was found that the precipitates at the grain boundaries are larger in size, higher in aspect ratios and maximum Feret diameter compared to the precipitates inside the grains, due to earlier nucleation of the precipitates at the grain boundaries. Our data on the precipitates at the interface between grains and Mg{sub 2}Si inclusion show that the surfaces of inclusion (impurity) particles can serve as a location for heterogeneous nucleation of precipitates. - Highlights: •Focused ion beam (FIB) tomography was used to characterize the microstructure of Al 7075 in three dimensions. •Analysis of grains and precipitates was performed in terms of volume, size, and morphology. •Precipitates at the grain boundaries have larger size and aspect ratio compared to the precipitates inside the grains.

36 MATERIALS SCIENCE↗

In situ melt pool measurements for laser powder bed fusion using multi sensing and correlation analysis

Laser powder bed fusion is a promising technology for local deposition and microstructure control, but it suffers from defects such as delamination and porosity due to the lack of understanding of melt pool dynamics. To study the fundamental behavior of the melt pool, both geometric and thermal sensing with high spatial and temporal resolutions are necessary. This work applies and integrates three advanced sensing technologies: synchrotron X-ray imaging, high-speed IR camera, and high-spatial-resolution IR camera to characterize the evolution of the melt pool shape, keyhole, vapor plume, and thermal evolution in Ti–6Al–4V and 410 stainless steel spot melt cases. Aside from presenting the sensing capability, this paper develops an effective algorithm for high-speed X-ray imaging data to identify melt pool geometries accurately. Preprocessing methods are also implemented for the IR data to estimate the emissivity value and extrapolate the saturated pixels. Quantifications on boundary velocities, melt pool dimensions, thermal gradients, and cooling rates are performed, enabling future comprehensive melt pool dynamics and microstructure analysis. The study discovers a strong correlation between the thermal and X-ray data, demonstrating the feasibility of using relatively cheap IR cameras to predict features that currently can only be captured using costly synchrotron X-ray imaging. Such correlation can be used for future thermal-based melt pool control and model validation.

47 OTHER INSTRUMENTATION↗

Acquisition of partial grain orientation information using optical microscopy

Optical microscopy (OM) is often the first technique used to characterize surfaces of materials because of its simplicity and low cost. However, the information obtained by OM is usually limited to the geometry and spatial distribution of microstructural features. We present an advanced OM technique to perform quantitative microstructure analysis of polycrystalline metals and to assess partial grain orientation information from measurements of reflectance over a range of incident light directions. Our technique relies on the collection of a series of optical micrographs under controlled illumination conditions. We find a marked direction-dependence of reflectance and ascribe it to sub-micron facets on the surfaces of individual grains. These surface facets are, in turn, correlated to grain orientation. We automate our technique via digital processing and numerical analysis of micrographs, enabling it to generate a wealth of microstructure data while remaining simple to use and inexpensive to implement.

36 MATERIALS SCIENCE↗

Synthesis of the Ti{sub 2}AlC MAX Phase with a Reduction Step via Combustion of a TiO{sub 2} + Mg + Al + C Mixture

Technologically viable principles have been developed for the preparation of the MAX phase Ti{sub 2}AlC by self-propagating high-temperature synthesis (SHS) with a reduction step, using titanium dioxide. We have studied the influence of synthesis conditions (starting-mixture composition and ratio of reactants) on the composition, structure, and particle size of Ti{sub 2}AlC powders. The results demonstrate that an excess of magnesium in the starting mixture leads to a decrease in the percentage of MgAl{sub 2}O{sub 4} (spinel), and carbon deficiency in the starting mixture reduces the percentage of titanium carbide in the final product. The Ti{sub 2}AlC powders prepared by SHS consist of agglomerates of layered particles differing in size: from coarse (several microns) to ultrafine and nanometer-sized particles. The composition of the powders was confirmed by chemical analysis, microstructural examination, and X-ray diffraction.

36 MATERIALS SCIENCE↗

Thermoelectric properties of indium doped PbTe{sub 1-y}Se{sub y} alloys

Lead telluride and its alloys are well known for their thermoelectric applications. Here, a systematic study of PbTe{sub 1-y}Se{sub y} alloys doped with indium has been done. The powder X-Ray diffraction combined with Rietveld analysis confirmed the polycrystalline single phase nature of the samples, while microstructural analysis with scanning electron microscope results showed densification of samples and presence of micrometer sized particles. The temperature dependent transport properties showed that in these alloys, indium neither pinned the Fermi level as it does in PbTe, nor acted as a resonant dopant as in SnTe. At high temperatures, bipolar effect was observed which restricted the zT to 0.66 at 800 K for the sample with 30% Se content.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

Effect of heat input on dissimilar welds of ultra high strength steel and duplex stainless steel: Microstructural and compositional analysis

The effect of heat input on the microstructure and compositional heterogeneity of welds of direct-quenched ultra high strength steel (Optim 960 QC) and duplex stainless steel (UNS S32205) was studied. The dissimilar welds were made using GMAW with a fully austenitic filler wire. In addition to grain coarsening in the heat affected zone (HAZ) of the ferritic side, it was found that an increase in heat input correlatively increased the proportional volume of bainitic to martensitic phases. Coarse ferritic grains were observed in the duplex HAZ. Higher heat input, however, had a beneficial effect on the nucleation of austenite in the HAZ. Heat input had a regulatory effect on grain growth within the austenitic weld and more favorable equiaxed austenite was obtained with higher heat input. On the ferritic side of the welds, macrosegregation in the form of a martensitic intermediate zone was observed for all the cooling rates studied. However, on the duplex side, macrosegregation in the fusion boundary was only noticed with higher cooling rates. Microstructural observations and compositional analysis suggest that higher heat input could be beneficial for the structural integrity of the weld despite higher heat input increasing the extent of adverse coarse grains in the HAZ, especially on the ferritic side. - Highlights: •The effect of heat input on dissimilar welds of UHSS and DSS was studied. •Transmutation of the microstructure was discussed in detail. •The influence of heat input on compositional heterogeneity of welds was described. •Higher heat input enhanced bainitic transformation on the ferritic side. •Macrosegregation was affected by the amount of heat input on the DSS side.

36 MATERIALS SCIENCE↗