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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 1,261 records · Page 70
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Preparation and Oxidation Performance of a NiCoCrAlYSiHf + NiAl Composite Coating Deposited by Arc Ion Plating and Magnetron Sputtering Techniques

A NiCoCrAlYSiHf+NiAl composite coating was deposited onto a second-generation single-crystal superalloy René N5 by methods of arc ion plating and magnetron sputtering. After vacuum annealing, the composite coating exhibited a gradient distribution of elements, in which Al was enriched in outer layer and Cr was enriched in inner layer. Compared with conventional NiCoCrAlYSiHf and β-NiAl coatings, the composite coating was evaluated in isothermal and cyclic oxidation tests at 1100 °C in ambient air. The results showed that the oxidation rate of the composite coating was lower than that of NiCoCrAlYSiHf coating. Meanwhile, the extent of interdiffusion between coating and substrate in the composite coating was slighter compared with that in the β-NiAl coating. Microstructure evolutions of the composite coating after annealing and further oxidation test are investigated.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Processing of Ultrafine-Grained Steels by Warm Rolling and Annealing

Low-carbon microalloyed steel was subjected to warm rolling followed by rapid transformation annealing (RTA) at 800-850 °C and subcritical annealing (SCA) at 600 °C to develop ultrafine ferrite grain structures (UFFG) with grain size less than 3 μm. The present study investigated the influence of light (40%) and heavy (80%) warm rolling deformation (LWR and HWR) applied during the finishing pass of two-pass rolling schedules on the microstructural evolution after rolling and subsequent annealing treatments. RTA treatment of HWR sample at a lower intercritical temperature for an optimum duration (800 °C, 30 s) developed UFFG-martensite dual-phase structure that offered the best combination of strength (YS ~ 900 MPa and UTS ~ 1200 MPa) and ductility (25% elongation). The SCA treatment provided sufficient time to achieve a uniform distribution of carbide particles throughout the ferrite matrix. SCA treatment of HWR at 600 °C for 4 h developed UFFG-carbide structure achieving YS of 800 MPa with 20% ductility. The SCA of LWR resulted in coarser ferrite grain structures (grain size > 5 μm) having higher ductility (more than 30%) but lower strength (UTS of 400-550 MPa) as compared to RTA.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Investigation on Equal-Channel Angular Pressing-Induced Grain Refinement in an Aluminum Matrix Composite Reinforced with Al-Cu-Ti Metallic Glass Particles

In the present study, a homogeneous ultrafine grain structure composite consisting of metallic glass particles reinforcements was developed by equal-channel angular pressing (ECAP) process. The microstructure of composite was characterized using x-ray diffraction (XRD), transmission electron microscopy (TEM) and electron backscatter diffraction (EBSD) techniques. The uniaxial compression test was used to determine the mechanical properties. The mechanisms of grain refinement during ECAP process were discussed based on the microstructural evolutions. A composite was successfully produced after four passes of ECAP, having an average grain size of 610 nm and compressive yield strength of 242 MPa. Also, the yield strength of composite after each pass was quantitatively estimated by considering all the effective strengthening mechanism. The findings showed that the dislocations strengthening mechanism with contribution of more than 50% plays a major role in strengthening the composite. There was a negligible gap between the experimental and theoretical values of yield strength for all ECAP pass numbers.

36 MATERIALS SCIENCE↗
DOE OSTI2019

The Application of Canned Deformation to a Hard-Deformed Spray-Deposited Al-Zn-Mg-Cu Alloy

A wide variety of industrial applications require Al-Zn-Mg-Cu alloys with high strength and ductility. However, Zn-rich Al-Zn-Mg-Cu alloys prepared by rapid solidification methods usually show excellent strength but poor formability, which restricts their wide application in complex forming. In this study, we developed a new deformation method for the spray-deposited Zn-rich Al-Zn-Mg-Cu alloy to avoid crack formation and achieve isotropic properties. The microstructure evolution and crystallographic textures were analyzed and compared with the results of a normal deformation process. Crack-free forgings with the ultimate tensile strength (UTS), yield strength (YS) and elongation of 727 ± 5 MPa, 690 ± 3 MPa, 5.0 ± 0.7% along the radial direction and 735 ± 2 MPa, 693 ± 3 MPa, 6.3 ± 0.2% along the tangential direction were finally obtained. The improvement in the mechanical properties can be attributed to the larger amount of subgrains and substructures generated in the canned deformed alloy. The results of this study show excellent advantages and potential application prospects of the canned deformation to hard-deformed Al-Zn-Mg-Cu alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Test Temperature and Strain Rate on Dynamic Mechanical Behavior of Aluminum Alloy 2519A

The dynamic mechanical behavior of aluminum alloy 2519A-T9I6 has been investigated by a split Hopkinson bar at temperature range from 298 to 523 K and at strain rates of from 10{sup 3} to 5 × 10{sup 3} s{sup −1} in this study. The results show that both the strain rate and test temperature have a significant effect on the dynamic behavior and microstructure evolution of aluminum alloy 2519A-T9I6. Under similar strain rate, the strengthening effect of strain rate decreases with the increase in the test temperature. Moreover, the dynamic yield strength at above 423 K drops sharply at the strain rate of about 5000 s{sup −1}, which is attributed to the flow softening caused by decomposition of θ′ precipitates at high strain rate and high temperature.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Hot Deformation Behavior of Aluminum Alloys AA7010 and AA7075

The hot deformation behavior of high-strength aluminum alloys AA7010 and 5 was studied through hot isothermal compression testing in the temperature regime of 623-723 K (at an interval of 25 K) and at varying strain rates (0.001 to 10 s{sup −1}). The safe zone of hot workability of both the alloys was determined using the instability criteria and correlating with the microstructure evolution. Zener–Hollomon parameters were calculated, and constitutive equations were also derived. Common characteristics observed in both the alloys were adiabatic shear band formation at a temperature of 623 K and strain rate of 10 s{sup −1} and flow localization at combination of all temperatures and high strain rate of 10 s{sup −1} with evolution of very fine recrystallized (DRX) grains. High-temperature resistance to deformation, large extent of recrystallization and relatively larger zone of stable deformation and higher activation energy in Al alloy AA7010 were observed as compared to AA7075. Considering the role of precipitates, dynamic recrystallization was found to have significant role in governing the hot deformation behavior of the alloys. Prediction of constitutive equations was found to be more accurate at higher temperatures and at moderate-to-high strain rates with relatively less error in AA7075 alloy as compared to AA7010 alloy.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Thermomechanical Behavior of Biocompatible Austenitic Stainless Steels during Simulated Torsion Tests

The thermomechanical behavior and the microstructural evolution during the hot deformation are important aspects of metal alloys during hot forging and rolling processes. Here, the correlation between dynamically recrystallized grain size (d{sub DRX}), steady-state stress (σ{sub ss}) and Zener–Hollomon (Z) parameter is investigated according to the Universal Derby–Ashby relationship. Specimens of a UNS S 31673 and a UNS S 31675 steels, used in the manufacture of orthopedic implants, were subjected to continuous isothermal torsion tests. A strain of 3.0 and strain rates of 0.01, 0.1, 1.0 and 10 s{sup −1} at temperatures of 1000, 1100 and 1200 °C, were employed. The results showed that the competition between the hardening and dynamic softening (i.e., recovery and recrystallization) mechanisms, as depicted by the flow curves, agreed with the Derby relation. This observation is also a consequence of the variation in the stacking fault energy (SFE) with the applied strain. Additionally, the influence of the hot deformation parameters on the shape of the curves and the grain refinement is governed by the balance between these thermally activated mechanisms.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Hot Deformation and Processing Maps of B{sub 4}C/6061Al Nanocomposites Fabricated by Spark Plasma Sintering

We developed 3 vol.% B{sub 4}C/6061Al nanocomposites by spark plasma sintering. We then characterized their flow and hot deformation behaviors using isothermal compression tests at deformation temperatures of 673-823 K and strain rates of 0.001-1 s{sup −1}. Results indicated that their steady flow characteristic can be described by the Zener–Hollomon parameter (Z) as a hyperbolic-sine function of flow stress. Based on pinning effect from B{sub 4}C nanoparticles, the estimated activation energy was calculated to be 274.80 kJ/mol. At the unstable deformation condition (723 K/1 s{sup −1}) with high Z, flow localization appeared; the main softening mechanisms involved are dynamic recovery and dynamic recrystallization (DRX). At the stable deformation condition (823 K/0.001 s{sup −1}) with low Z, adequate DRX occurred. Based on the processing map and microstructure evolution, the optimum hot working conditions for B{sub 4}C/6061Al nanocomposites were determined to be a deformation temperature of 773-823 K and a strain rate of 0.001-0.003 s{sup −1}. These working conditions were verified by a hot extrusion test.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Constitutive Modeling of the Hot Deformation Behavior in 6082 Aluminum Alloy

The hot compressive tests of 6082 aluminum alloy were conducted on a Gleeble-3500 thermomechanical simulator at temperature ranges of 380-530 °C and strain rate range of 0.01-10 s{sup −1}. The constitutive analysis and microstructural evolution of the alloy were investigated. It was indicated that the peak stress increased with increasing strain rate and decreasing temperature. Dynamic recovery and dynamic recrystallization lead to the softening behavior of the alloy. In order to characterize the flow behavior of this alloy, some models were established based on the experimental data including the phenomenological Arrhenius-type model, the physically based Estrin and Mecking (EM) model for work hardening and dynamic recovery, and the EM model, which was combined with the Avrami equation for dynamic recrystallization. An artificial neural network model was also established to predict the flow stress. The results indicate that the Arrhenius-type model is more simple and more efficient than the EM + Avrami model. Moreover, the well-trained ANN model has the best predicting performance.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Long Term Creep Behavior of a CoCrFeNiMn High Entropy Alloy

The potential of high entropy alloys (HEAs) to meet or exceed austenitic stainless-steel performance with the additional benefit of improved hot corrosion/oxidation resistance makes FCC HEAs attractive for use in energy applications. While shorter term creep tests have been reported in the literature on HEAs, not all methodologies utilize repeatable techniques. This manuscript reports on over 23,500 accumulated hours of tensile creep testing with adherence to ASTM standards on a melt solidified ingot of CoCrFeNiMn HEA converted to wrought plate using conventional thermo-mechanical processing techniques. The typical standard creep analyses are reported, i.e., Larson-Miller parameter, Monkman-Grant relationship, activation energy for creep, and creep stress exponents were calculated and compared to previously reported short-term creep tests. Additionally, characteristics of creep fracture and microstructural evolution are reported with cursory dislocation mechanisms investigated.

Rozman, Kyle A.↗
DOE OSTI2024

Neutron Diffraction Residual Stress Study of a AA2219-T87 Self-Reacting Friction Stir Weld

2219-T87 is a precipitation hardenable aluminum-copper alloy which sees wide use in structural aerospace components. Thick panels of this alloy are joined via self-reacting friction welding (SRFSW); however, this thermomechanical process can result in significant loss of the alloy’s strengthening precipitates and large residual stresses which are detrimental to mechanical behavior and performance. High-resolution maps of the residual strain and stress states along the normal, transverse, and longitudinal directions of 2219-T87 SRFSW were obtained using neutron diffraction measurements. Residual stress had the highest tensile value in the heat-affected zone (HAZ) and the largest compressive stress in the base metal region of the normal and transverse directions. Line profile residual stress distributions displayed an “M”-shaped distribution in each direction with the longitudinal direction being the most pronounced while 2D residual stresses displayed an hourglass-shaped pattern. Further, average maximal longitudinal residual stress values ranged from 60.6 to 85.6% of yield. Microhardness testing across the transverse weld section produced a “V”-shaped curve with slight hardness recovery in the stir zone. Maximal and minimal microhardness values were observed in the base metal (154 HV) and thermomechanically affected zone (82 HV), respectively. Microstructural evolution was recorded using optical microscopy and showed decreasing grain size from the HAZ to the stir zone.

36 MATERIALS SCIENCE↗
DOE OSTI2015

In Situ TEM Nanoindentation Studies on Stress-Induced Phase Transformations in Metallic Materials

Though abundant phase transformations are in general thermally driven processes, there are many examples wherein stresses can induce phase transformations. We applied numerous in situ techniques, such as in situ x-ray diffraction and neutron diffraction in order to reveal phase transformations. Recently, an in situ nanoindentation technique coupled with transmission electron microscopy demonstrated the capability to directly correlating stresses with phase transformations and microstructural evolutions at a submicron length scale. We briefly review in situ studies on stress-induced diffusional and diffusionless phase transformations in amorphous CuZrAl alloy and NiFeGa shape memory alloy. Moreover, in the amorphous CuZrAl, in situ nanoindentation studies show that the nucleation of nanocrystals (a diffusional process) occurs at ultra-low stresses manifested by a prominent stress drop. In the NiFeGa shape memory alloy, two distinctive types of martensitic (diffusionless) phase transformations accompanied by stress plateaus are observed, including a reversible gradual phase transformation at low stress levels, and an irreversible abrupt phase transition at higher stress levels.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Discontinuous Precipitation in U-10 wt.%Mo Alloy: Reaction Kinetics, Effect of Prior gamma-UMo Microstructure, the Role of Grain-Boundary Misorientation, and the Effect of Ternary Alloying Addition

Eutectoid transformation in U-10 wt.% Mo (U10Mo) alloy initiates through discontinuous precipitation (DP) resulting in the formation of a lamellar microstructure that consists of an a-U and Mo-enriched bcc ?-UMo phase along the prior ?-UMo grain boundaries. DP is the main mode of transformation at 500°C. However, continuous precipitation (CP) of ?’ U2Mo phase together with grain-boundary DP is observed at 400°C. The reaction kinetics are noted to be very sluggish at 400°C compared to 500°C. The degree of eutectoid transformation is related to the prior ?-UMo grain size, and a smaller average grain size leads to a larger amount of transformation at a given reaction temperature. Minor addition (0.2 wt.%) of a third alloying element (Cr, Ni, Co) leads to significant changes in the nature of the DP mechanism in U10Mo alloy. In addition, high-angle grain boundaries with a misorientation of 30–45° are observed to be the major DP initiation sites. The microstructural evolution of U10Mo alloy with regard to DP-based reaction is discussed.

Jana, Saumyadeep↗
DOE OSTI2023

Establishing a Design Strategy for Corrosion Resistant Structural Materials in Molten Salt Technologies

To address the gap in material design strategies for structural components in molten salt-powered technologies, the current work aimed to identify key parameters governing corrosion induced degradation of materials during exposures in molten halide salts. The applicability of the data on dissolution rates of pure metals (e.g., Cr) in a given molten salt to enable predictions of corrosion behavior of multicomponent binary and ternary Fe-based model and Ni-based commercial alloys isothermally exposed in the purified KCl-MgCl 2 in quartz capsules at 700 and 800°C was evaluated. The influence of alloy chemistry on initial dissolution rates and the consequent impact on the time-dependent corrosion induced microstructural evolution in the alloy subsurface was predicted with a coupled thermodynamic-kinetic model. Finally, the model was well able to predict the Cr depletion in all investigated alloys demonstrating the ability of the proposed approach to enable a unique design strategy for structural materials in molten salts.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Solute redistribution and phase stability at FeCr/TiO 2–x interfaces under ion irradiation

Cr diffusion in trilayer thin films of 100 nm Fe–18Cr/125 nm TiO 2–x /100 nm Fe–18Cr deposited on MgO substrates at 500 °C was studied by either annealing at 500 °C or Ni 3+ ion irradiation at 500 °C. Microchemistry and microstructure evolution at the metal/oxide interfaces were investigated using (high-resolution) transmission electron microscopy, energy-dispersive X-ray spectroscopy and electron energy loss spectroscopy. Diffusion of Cr into the O-deficient TiO 2 layer, with negligible segregation to the FeCr/TiO 2–x interface itself, was observed under both annealing and irradiation. Cr diffusion into TiO 2–x was enhanced in ion-irradiated samples as compared to annealed. Irradiation-induced voids and amorphization of TiO 2–x was also observed. The experimental results are rationalized using first-principles calculations that suggest an energetic preference for substituting Ti with Cr in sub-stoichiometric TiO 2 . Furthermore, the implications of these results on the irradiation stability of oxide-dispersed ferritic alloys are discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Detecting self-ion irradiation-induced void swelling in pure copper using transient grating spectroscopy

Irradiation-induced void swelling remains a major challenge to nuclear reactor operation. Swelling may take years to initiate and often results in rapid material property degradation once started. Alloy development for advanced nuclear systems will require rapid characterization of the swelling breakaway dose in new alloys, yet this capability does not yet exist. In this paper, we demonstrate that transient grating spectroscopy (TGS) can detect void swelling in single crystal copper via changes in surface acoustic wave (SAW) velocity. Scanning transmission electron microscopy (STEM) links the TGS-observed changes with void swelling-induced microstructural evolution. Finally, these results are considered in the context of previous work to suggest that in situ TGS will be able to rapidly determine when new bulk materials begin void swelling, shortening alloy development and testing times.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2018

Energetics of native defects, solute partitioning, and interfacial energy of Q precipitate in Al-Cu-Mg-Si alloys

The compound Al 3 Cu 2 Mg 9 Si 7 , is known as the Q-phase and forms as a thermodynamically stable precipitate during aging in the quaternary Al-Cu-Mg-Si system. We perform atomic-scale density functional theory (DFT) calculations of defect properties, solute partitioning, and interfacial stability of the Al 3 Cu 2 Mg 9 Si 7 (Q) precipitate. We find: (i) simple native point defect (i.e., vacancies and anti-sites) thermodynamics can partially explain the experimentally observed off-stoichiometry, such as the observed variation of compositions, Al 3+δ Cu 2 Mg 9-δ Si 7 (Mg-deficient and Al-rich) in experiment. (ii) Calculated solute-partitioning energies of common solutes allow us to define general rules for site-preference in the Q-phase in terms of electronic structure and atomic radius. To validate our DFT predictions, we perform atom-probe tomography (APT) experiments for six-different elements (Zn, Ni, Mn, Ti, V, and Zr). The results show that the partitioning behavior of solutes Ni, Zn, and Mn are consistent with DFT predictions, but the transition elements (Ti, V, and Zr), which are anomalously slow diffusers in Al, partition to the Q-phase in constrast to DFT partitioning energies. (iii) For the low energy interface ($11\bar{2}$) Q //(510) Al observed in needle shaped Q-precipitate, we survey various terminations and orientations and derive a low-energy interfacial structure. Here we find this low-energy interfacial model has Cu atoms nearest to the interface, which is in agreement with previous literature on Cu interfacial segregation at the Q'//α-Al interface. The computed interfacial energy (0.52 J/m 2 ) and the corresponding structure will be useful input to future multi-scale modeling of microstructural evolution.

36 MATERIALS SCIENCE↗