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DOE OSTI2021

Manipulation and statistical analysis of the fluid flow of polymer semiconductor solutions during meniscus-guided coating

Recent work in structure–processing relationships of polymer semiconductors have demonstrated the versatility and control of thin-film microstructure offered by meniscusguided coating (MGC) techniques. Here, we analyze the qualitative and quantitative aspects of solution shearing, a model MGC method, using coating blades augmented with arrays of pillars. The pillars induce local regions of high strain rates—both shear and extensional—not otherwise possible with unmodified blades, and we use fluid mechanical simulations to model and study a variety of pillar spacings and densities. We then perform a statistical analysis of 130 simulation variables to find correlations with three dependent variables of interest: thin-film degree of crystallinity and transistor field-effect mobilities for charge-transport parallel (Μ para ) and perpendicular (Μ perp ) to the coating direction. Our study suggests that simple fluid mechanical models can reproduce substantive correlations between the induced fluid flow and important performance metrics, providing a methodology for optimizing blade design.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Quantitative analysis of Raman spectral parameters for carbon fibers: practical considerations and connection to mechanical properties

Although the literature on the Raman spectra of carbon fibers is vast, no consistent, robust predictive relationship between mechanical properties of carbon fibers and spectral parameters exists. This shortcoming is due to the use of numerous fitting functions to evaluate Raman spectra of carbon fibers and the inconsistencies in establishing the best fitting models in a statistically robust fashion. To address this gap, we present a comprehensive work on the Raman spectra of carbon fibers that combines a vast library of experimental data with a robust numerical analysis and a statistical evaluation of a wide range of suggested fitting models. This manuscript begins with a brief review of the commonly applied fitting models. Then, the Raman spectra of 32 commercially available polyacrylonitrile-based carbon fibers collected at excitation wavelengths 532, 633, and 785 nm are presented and the best fit for all fibers is evaluated based on several statistical criteria in conjunction with numerical calculations and physical arguments. The results suggest that high-performance fibers must be fit with at least five peaks, whereas high-tensile modulus fibers are best fit with at least six distinct peaks. Finally, we employ simultaneous fitting of the Raman spectra of specific fibers and wavelengths and demonstrate that strong correlations exist between mechanical properties and the D1 peak position and shape across the range of evaluated mechanical properties. Finally, we suggest straightforward improvements in fitting analysis procedures that can be implemented to increase coherency in the understanding of the underlying carbon fiber microstructure intuited from Raman spectroscopy.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Investigating the failure behavior of cast Al-11Ce-0.4Mg alloys using in-situ scanning electron microscopy tensile testing

Within the last decade, research on Al-Ce-Mg alloys has reported promising results for use in cast part applications. In this paper, the failure behavior of cast Al-11Ce-0.4Mg (wt%) was investigated experimentally with focus on the effect the matrix and intermetallic phases have on the fracture propagation behavior at failure. For the first time, in-situ SEM tensile testing was used to study the failure behavior of cast Al-Ce alloys, reporting results for uniaxial, DIC, and single edge notch tensile tests. The results of the in-situ SEM tensile testing were compared with the materials characterization experiments, which included serial sectioning, EBSD, EDS, and fractography. Analysis of EBSD and EDS mapping of cast Al-11Ce-0.4Mg showed that the cast microstructure was a hypereutectic two phase Al-Ce alloy with grains encompassing large complex colonies of laminar eutectic Al 11 Ce 3 intermetallic. The uniaxial tensile results reported the effect casting defects have on the strength and ductility of the alloy, and DIC in-situ testing showed that the eutectic colonies plastically deform less than the matrix phase. In-situ SEM single edge notch tensile testing displayed how the strength of an individual phase affected the crack propagation direction in the alloy. The results of both the materials characterization and in-situ tensile testing experiments on the failure of this alloy revealed further directions for future alloy development that can improve both the strength and fracture toughness of Al-Ce-Mg alloys.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Enhanced Stress Relaxation Behavior via Basal ⟨a⟩ Dislocation Activity in Zircaloy-4 Cladding

Herein this work evaluates the stress relaxation behavior of textured Zircaloy-4 cladding to understand how mechanical anisotropy influences pellet-cladding interactions. Uniaxial and biaxial stress relaxation tests are performed using full-tube axial tension and internal pressurization, respectively, aiming to achieve 0.25%, 1%, and 2% equivalent strains in the cladding samples at a temperature of 300°C. Internal pressure relaxation test results display enhanced stress relaxation compared to axial testing results, particularly for samples loaded beyond yield. Results of electron backscatter diffraction indicate increased deformation microstructure during loading and increased strain homogenization and recovery during relaxation for samples loaded via internal pressurization. Analysis indicates that the increased production and activity of basal ⟨a⟩ dislocations play a significant role in the enhanced relaxation measured in samples subjected to internal pressurization.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Fast ionic conduction achieved through the design and synthesis of ceramic heterointerfaces

Lithium (Li) chloride and iron oxychloride (FeOCl), typically nonconductive, were combined to form a [Li 1+δ Cl] δ+ /[FeOCl] δ- heterointerface composite material (LFH), achieving ionic conductivities of >1 mS cm -1 . Analysis techniques (scanning transmission electron microscopy [STEM] and electron energy-loss spectroscopy [EELS]) indicated that the microstructure of LFH consisted of an amorphous LiCl-based shell surrounding a crystalline FeOCl-based core. Electrochemical measurements alongside solid-state 6,7 Li nuclear magnetic resonance (NMR) and molecular dynamic simulations revealed Li+ as the sole conductive species, with a diffusion barrier of ~0.25 eV. X-ray photoelectron spectroscopy (XPS) and X-ray absorption fine structure (XAFS) results further supported interstitial Li + diffusion at the heterointerface and within the LiCl phase, made possible by the heterointerface. Despite susceptibility to electronic conductivity, iron’s defects and multivalency (Fe³⁺, Fe²⁺) enable the Fe–O–Cl framework to accept Cl - , facilitating Li⁺ ionic conduction. Finally, a prototype solid-state cell (showing 97% Coulombic efficiency) demonstrated the viability of this heterointerface design for applications in energy storage.

36 MATERIALS SCIENCE↗

DOE OSTI2013

Effects of (Al,Ge) double doping on the thermoelectric properties of higher manganese silicides

Experiments and analysis have been carried out to investigate the effects of Al and (Al,Ge) doping on the microstructure and thermoelectric properties of polycrystalline higher manganese silicide (HMS) samples, which were prepared by solid-state reaction, ball milling, and followed by spark plasma sintering. It has been found that Al doping effectively increases the hole concentration, which leads to an increase in the electrical conductivity and power factor. By introducing the second dopant Ge into Al-doped HMS, the electrical conductivity is increased, and the Seebeck coefficient is decreased as a result of further increased hole concentration. The peak power factor is found to occur at a hole concentration between 1.8 × 10{sup 21} and 2.2 × 10{sup 21} cm{sup −3} measured at room temperature. The (Al,Ge)-doped HMS samples show lower power factors owing to their higher hole concentrations. The mobility of Mn(Al{sub 0.0035}Ge{sub y}Si{sub 0.9965-y}){sub 1.8} with y = 0.035 varies approximately as T{sup −3/2} above 200 K, suggesting acoustic phonon scattering is the dominant scattering mechanism. The thermal conductivity of HMS does not change appreciably by Al or (Al,Ge) doping. The maximum ZT of (Al,Ge)-doped HMS is 0.57 at 823 K, which is similar to the highest value found in the Al-doped HMS samples. The ZT values were reduced in the Mn(Al{sub 0.0035}Ge{sub y}Si{sub 0.9965-y}){sub 1.8} samples with high Ge concentration of y = 0.025 and 0.035, because of reduced power factor. In addition, a two-band model was employed to show that the hole contribution to the thermal conductivity dominates the bipolar and electron contributions for all samples from 300 to 823 K and accounts for about 12% of the total thermal conductivity at about 800 K.

36 MATERIALS SCIENCE↗

DOE OSTI2019

PHENIX U.S.-Japan Collaboration Investigation of Thermal and Mechanical Properties of Thermal Neutron–Shielded Irradiated Tungsten

The United States and Japan have collaborated on fusion materials research in a series of agreements reaching back to 1981. The PHENIX collaboration is the latest U.S.-Japan project which spans 2013 to 2019 and has the goal of assessing technical feasibility of tungsten-based, helium-cooled plasma-facing component concepts for a demonstration fusion power reactor (DEMO). Task 2 within the PHENIX project is focused on evaluating the neutron irradiation effects in tungsten. For tungsten, the transmutation to Re and Os is at least as important to determining its properties after irradiation as the displacement damage, and the transmutation rate depends on the energy spectrum of the reactor. A large-scale, instrumented irradiation capsule with thermal neutron shielding to better mimic fusion conditions was irradiated in the High Flux Isotope Reactor (HFIR) at Oak Ridge National Laboratory. The tungsten specimens were irradiated in different temperature zones between 500°C and 1200°C to doses of ~0.2 to 0.7 displacements per atom. More than 20 varieties of pure tungsten and tungsten alloys were included in the irradiation, and they were evaluated in the 3025E hot-cell facility and at the Low Activation Materials Development and Analysis Laboratory. The elevated temperature tensile, fracture toughness, hardness, thermal conductivity, electrical resistivity, density, elemental composition, and microstructure properties of the irradiated materials are being collected. Furthermore, this paper overviews the experimental design, specimen matrix, and the initial results of postirradiation examinations.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2014

Thermal Conductivity in Nanocrystalline Ceria Thin Films

The thermal conductivity of nanocrystalline ceria films grown by unbalanced magnetron sputtering is determined as a function of temperature using laser-based modulated thermoreflectance. The films exhibit significantly reduced conductivity compared with stoichiometric bulk CeO2. A variety of microstructure imaging techniques including X-ray diffraction, scanning and transmission electron microscopy, X-ray photoelectron analysis, and electron energy loss spectroscopy indicate that the thermal conductivity is influenced by grain boundaries, dislocations, and oxygen vacancies. The temperature dependence of the thermal conductivity is analyzed using an analytical solution of the Boltzmann transport equation. The conclusion of this study is that oxygen vacancies pose a smaller impediment to thermal transport when they segregate along grain boundaries.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2026

Comparative study on the formation of Cr and Ti ohmic contacts to (001) β -Ga 2 O 3

Here, a comparative study of Cr/Au and Ti/Au ohmic contacts on (001) β-Ga 2 O 3 was conducted. The electrical behavior from current-voltage measurements and the interfacial composition and microstructure as determined from high-resolution transmission electron microscopy (TEM) with energy dispersive x-ray analysis were compared for the different contacts at selected points in an annealing series (300–700 °C, 1 min. anneals in N 2 ). Cr/Au contacts became ohmic at temperatures (300–350 °C) approximately 50–100 °C lower than Ti/Au contacts (400–450 °C). Cr/Au and Ti/Au contacts demonstrated optimal ohmic behavior (lowest resistance) when annealed to 450–500 and 500–600 °C, respectively, with Ti/Au contacts yielding a lower total resistance than Cr/Au. Cross-sectional TEM images of Cr/Au contacts annealed at 450 °C revealed the presence of Au nanoclusters at the Ga 2 O 3 interface and CrO x layers at both the top of the contact and the Ga 2 O 3 interface. Whereas TiO x also formed at the top and bottom interfaces in 450 °C-annealed Ti/Au contacts, the TiO x surface layer appeared to be variable in thickness and/or discontinuous, unlike the CrO x surface layer. Au nanoclusters were not detected at the interface in the Ti/Au contacts. The interdiffusion and oxidation observed in both contact metallizations point to the need for diffusion barriers that may allow these contacts to be used in future Ga 2 O 3 -based devices that operate at elevated temperatures.

36 MATERIALS SCIENCE↗

DOE OSTI2019

High Dose Irradiation of Austenitic Alloys

The present report provides a short summary of our recent efforts to irradiate an austenitic iron alloy, D9, and a face-center cubic high entropy alloy (HEA) to a damage level of 400 peak dpa. The irradiated microstructure of D9 showed little void swelling and the presence of a large density of carbides in the irradiated region. This indicated a potential issue either with the irradiation environment (i.e. chamber contamination) or specimen preparation. The HEA examined showed very little swelling in the matrix and possibly no carbides. Further examination of the microstructure revealed the formation of numerous precipitates that are coherent with the matrix based on diffraction pattern analysis. In this temperature range, the lack of swelling and formation of these precipitates indicates the superior radiation resistance of this HEA alloy.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Seeing is Believing: Autonomous Microscopy and the Data Revolution in Materials Science

This presentation explores the transformative potential of autonomous electron microscopy and artificial intelligence (AI) in accelerating materials science discovery, particularly for energy applications and materials operating in extreme environments. We discuss pioneering self-driving laboratories at NREL designed to intelligently probe material synthesis and degradation across multiple scales, aiming to rapidly bridge the gap between atomic-level understanding and the development of high-performance, reliable materials. Utilizing advanced machine learning techniques, such as few-shot learning and multimodal analysis integrating imaging and spectroscopy, we demonstrate methods to extract actionable descriptors for material behavior, quantify complex microstructural evolution, and statistically link synthesis parameters to defect populations. This AI-driven approach promises to accelerate the creation of predictive materials tailored for specific missions, enabling faster development cycles and enhanced material assurance.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Seeing is Believing: Autonomous Microscopy and the Data Revolution in Materials Science

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2019

Determination of the structure-processing-properties relationship of Fe-6.5wt%Si

The role of Fe-6.5wt%Si as a soft magnetic material in motor and power generation will continue to increase as power and efficiency demands keep increasing due to high silicon steel’s superior magnetic and electrical properties when operated at high frequencies. However, the presence of brittle phases creates challenges for mass production of the materials and for machining the materials into parts with demanding geometries. Understanding the processing parameters controlling the presence of the brittle phases is necessary to promote high silicon steels as the superior soft magnetic material. This research pioneers the use of in-situ cooling rate thermal imaging analysis and a 2D Laue x-ray detector to quantify the relationship among processing parameters, final microstructure of melt-spun ribbons and the associated physical properties. These techniques reveal the superlattice peaks of the ordered B2/D03 phases separating them from the background A2 phase. Utilizing a variety of techniques investigating mechanical, electrical, and magnetic properties’ correlation to crystal structure alongside processing parameters a time temperature transformation curve can be generated.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2019

The Influence of Temperature on the Cyclic Properties of the Transversely Isotropic Nanocomposite System Under Kinematic Harmonic Loading

A micromechanical model is developed to determine the effective inelastic properties of nanocomposites under monoharmonic deformation by taking into account the detailed microstructural geometries and constitutive models of the constituents. By using the correspondence principle in viscoelasticity and the modified Mori–Tanaka method, the effects of interface between the inclusion and the matrix are taken into account. By applying the developed model, we perform the numerical analysis aimed at the determination of complex moduli for a polymeric nanocomposite reinforced with nanofibers composed from carbon nanotubes under the isothermal conditions. The dependences of complex moduli on temperature and the amplitude of strain intensity are analyzed. The composites reinforced with unidirectionally aligned nanofibers are considered. The accumulated results demonstrate a strong dependence of the storage and loss moduli on temperature within a broad temperature range. The storage and loss moduli are found to monotonically increase with the volume fraction of nanofibers. At the same time, they decrease as temperature increases. The obtained results show that the strength of material decreases as temperature increases in the elastic and inelastic regions and the inelastic behavior occurs for lower strain amplitude as temperature increases.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

DOE OSTI2011

Cu-Ce-O mixed oxides from Ce-containing layered double hydroxide precursors: Controllable preparation and catalytic performance

Cu/Zn/Al layered double hydroxide (LDH) precursors have been synthesized using an anion exchange method with anionic Ce complexes containing the dipicolinate (pyridine-2,6-dicarboxylate) ligand. Cu-Ce-O mixed oxides were obtained by calcination of the Ce-containing LDHs. The materials were characterized by X-ray diffraction, Fourier transform infrared spectroscopy, X-ray photoelectron spectroscopy, thermogravimetry-differential thermal analysis, elemental analysis, and low temperature N{sub 2} adsorption/desorption measurements. The results reveal that the inclusion of Ce has a significant effect on the specific surface area, pore structure, and chemical state of Cu in the resulting Cu-Ce-O mixed metal oxides. The resulting changes in composition and structure, particularly the interactions between Cu and Ce centers, significantly enhance the activity of the Ce-containing materials as catalysts for the oxidation of phenol by hydrogen peroxide. - Graphical Abstract: Cu-Ce-O mixed oxides calcined from [Ce(dipic){sub 3}]{sup 3-}- intercalated Cu/Zn/Al layered double hydroxides were synthesized and displayed good catalytic performances in phenol oxidation due to the Cu-Ce interactions. Highlights: Black-Right-Pointing-Pointer [Ce(dipic){sub 3}]{sup 3-}-intercalated Cu/Zn/Al layered double hydroxides were synthesized. Black-Right-Pointing-Pointer Cu-Ce-O mixed oxides derivated from the LDHs were characterized as catalysts. Black-Right-Pointing-Pointer Presence of Ce influenced physicochemical property and catalytic performance. Black-Right-Pointing-Pointer Cu-Ce interaction was largely responsible for enhanced catalytic ability.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

On the bulk compaction of brittle granular materials, part I: SeS analysis of axial compression to 4000 MPa

The bulk compaction of granular materials has been studied for decades to interpret and manage responses for soils and powder-based component fabrication, and geophysical, celestial, and ballistic impact. Their bulk or macroscopic compaction response is limited by what occurs at the granular or microstructural scale. Motivation existed to more closely examine that association specific to granular brittle materials (e.g., ceramics and glasses). That examination is offered in a series of three companion papers where Part I describes a new supplemental analysis adopted to bulk compaction response involving relatively high compaction stresses (4000 MPa). Bulk compactions of vitreous silicates and crystalline quartzes were interpreted in three ways, including that of a new analysis that considers the product of void ratio (e) and stress (S) as a function of S, hereafter referred to as “SeS analysis”. In conclusion, the SeS analysis was found to be an informative supplement to conventional bulk compaction analyses because it provides more consistent higher sensitivity for the identification of bulk density rate increase with increasing compaction (softening); a rate increase that arises from the cumulative effect of the onsets and progression of compaction-induced yielding, fracture or comminution, densification, phase change, or combinations thereof occurring at the granular or microstructural scale.

compaction↗

DOE OSTI2012

Observation of columnar microstructure in lattice-matched InAlN/GaN grown by plasma assisted molecular beam epitaxy

Nominally lattice matched InAlN/GaN was grown by plasma-assisted molecular beam epitaxy, and the intrinsic microstructure was investigated via x-ray diffraction, transmission electron microscopy, and atom probe tomography. The InAlN showed a cellular structure, which was comprised of ~10 nm wide Al-rich cores and ~1 nm In-rich InAlN intercellular boundaries. Despite the strong laterally non-uniform In distribution, both vertical and lateral lattices are unperturbed by the cellular structure, as evidenced by strong thickness fringes in on-axis ω-2θ high resolution x-ray diffraction scans, coherence lengths derived from on-axis (0002) and off-axis (10{anti 1}2) ω-2θ high resolution x-ray diffraction scans, and a modified Williamson-Hall analysis for on-axis reflections.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Phase separation during the direct powder bed fusion of SiC

Powder bed fusion (PBF) is an attractive additive manufacturing option for fabrication of SiC object with complex geometries. However, the density and microstructure controls remain a challenge. This study is aimed at understanding laser–SiC interactions, with emphasis on microstructure-processing relationships, to identify potential solutions for the process improvement. SiC tubes were fabricated by PBF of pure SiC powders without sintering additives. Further, comprehensive analysis by X-ray diffraction, Raman spectroscopy, and electron microscopy indicated that binding of SiC particles was achieved by incongruent melting of SiC to a Si/C mixture containing SiC micro- and nanocrystallites. The phase evolution under laser irradiation of SiC was explained by phase diagrams. This study uncovered the PBF SiC microstructure at different length scales and the relationship between the microstructure and the processing parameters.

36 MATERIALS SCIENCE↗