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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 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2015

Microstructural Characterization of the U-9.1Mo Fuel/AA6061 Cladding Interface in Friction-Bonded Monolithic Fuel Plates Irradiated in the RERTR-6 Experiment

Low-enrichment (U-235 < 20%) U-Mo monolithic fuel is being developed for use in research and test reactors. The earliest design for this fuel that was investigated via reactor testing was comprised of a nominally U-10Mo fuel foil encased in AA6061 (Al-6061) cladding. For a fuel design to be deemed adequate for final use in a reactor, it must maintain dimensional stability and retain fission products throughout irradiation, which means that there must be good integrity at the fuel foil/cladding interface. To investigate the nature of the fuel/cladding interface for this fuel type after irradiation, fuel plates that were tested in INL's Advanced Test Reactor (ATR) were subsequently characterized using optical metallography, scanning electron microscopy, and transmission electron microscopy. Results of this characterization showed that the fuel/cladding interaction layers present at the U-Mo fuel/AA6061 cladding interface after fabrication became amorphous during irradiation. Up to two main interaction layers, based on composition, could be found at the fuel/cladding interface, depending on location. After irradiation, an Al-rich layer contained very few fission gas bubbles, but did exhibit Xe enrichment near the AA6061 cladding interface. Another layer, which contained more Si, had more observable fission gas bubbles. Adjacent to the AA6061 cladding were Mg-rich precipitates, which was in close proximity to the region where Xe is observed to be enriched. In samples produced using a focused ion beam at the interaction zone/AA6061 cladding interface were possible indications of porosity/debonding, which suggested that the interface in this location is relatively weak.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

Microstructural Characterization of Al 4 C 3 in Aluminum-Graphite Composite Prepared by Electron-Beam Melting

We prepared graphite infused aluminum composites by electron-beam vacuum melting and electromagnetic stirring with 0% and 4wt% graphite addition. Bulk density of 2.69 g/cm 3 was measured for samples with 0% graphite addition (AlCv0) and 2.66 g/cm 3 for samples with 4 wt% graphite addition (AlCv4). Both are >99% of their theoretical values. X-ray diffraction indicated that AlCv0 is phase pure, while the AlCv4 sample is a composite consisting of aluminum, Al 4 C 3 , and graphite. Electron microscopy and energy dispersive X-ray spectroscopy revealed pockets of carbon rich phase of 10 to 50 μm in sizes dispersed in the Al matrix in AlCv4. Scanning transmission electron microscopy (STEM) showed that Al 4 C 3 crystallites of 1-2 μm sizes that are mostly located near the outer shell of the pockets of carbon rich phase and with undissolved graphite at the center. Thermal conductivity of 107.8 W/m·K was measured for the AlCv4 and 226.7 W/m·K for the AlCv0. Our work demonstrated the feasibility of producing pore-free high density graphite infused aluminum composite materials by electron-beam melting and electromagnetic stirring in vacuum.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Non-destructive compositional and microstructural characterization of Sardinian Bronze Age swords through Neutron Diffraction

Highlights: • Determination of the manufacturing technique of some “Sa Idda” swords • New data on their provenience • Determination of: alloy composition, dendritic segregation, mineralization phase - Abstract: The Monte Sa Idda type swords belong to a well characterized typological class, whose origin has long been debated and seems to coincide with the Iberian Peninsula. The name comes from the site of the first discovery of a hoard containing this type of swords, among other bronze artefacts, namely Monte Sa Idda, Decimoputzu-Cagliari, Italy. The swords were produced through fusion inside a casting mould. Such kind of casting mould has not been found in Sardinia, and this may suggests that finished objects were either imported or made using clay or sand casting mould. Moreover, the discovery of these types of sword, in hoards and in votive deposits, raises the problem of their functional use. It is unknown if the blades were intended to be used as weapons, and therefore subjected to cold working necessary for thinning and sharpening of the blade, or as ceremonial objects. In order to answer to these questions, a neutron diffraction experiment was performed on three swords belonging to the Monte Sa Idda type. The results obtained are presented and discussed in the paper.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Microstructure characterization of Al–Cr–Fe quasicrystals sintered using spark plasma sintering

In this study, Al–Cr–Fe powders were consolidated using spark plasma sintering at different temperatures (650 °C, 700 °C, 750 °C and 800 °C). The sintered samples were investigated using X-ray diffraction (XRD), scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDX) and transmission electron microscopy (TEM). The porosity of the pellets is very sensitive to the sintering temperature: it reduces sharply from around 29.3% to around 3.1% when the sintering temperature increases from 650 °C to 700 °C probably due to the softening of quasicrystals at elevated temperatures. Metastable icosahedral Al–Cr–Fe transforms to stable decagonal Al–Cr–Fe in sintering process. Stable icosahedral Al–Cr–Fe forms in the samples sintered at 700 °C, 750 °C and 800 °C. Both stable quasicrystalline phases form through the nucleation and growth process in the sintering process. Selected area electron diffraction (SAED) analysis shows that the icosahedral phase and the decagonal phase formed in the sintering process have a quasilattice constant of about 0.45 nm and 1.2 nm, respectively. - Highlights: • Al–Cr–Fe quasicrystals were sintered using spark plasma sintering. • Metastable icosahedral Al–Cr–Fe transforms to decagonal Al–Cr–Fe during sintering. • Stable icosahedral Al–Cr–Fe forms during sintering at 700 °C to 800 °C. • Strain softening of quasicrystals at high temperature promotes SPS sintering.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Synthesis and microstructure characterization of Ni-Cr-Co-Ti-V-Al high entropy alloy coating on Ti-6Al-4V substrate by laser surface alloying

Ni-Cr-Co-Ti-V-Al high-entropy alloy coating on Ti-6Al-4V was synthesized by laser surface alloying. The coating is composed of a B2 matrix and (Co, Ni)Ti{sub 2} compounds with few β-Ti phases. Focused ion beam technique was utilized to prepare TEM sample and TEM observations agree well with XRD and SEM results. The formation of HEA phases is due to high temperature and rapid cooling rate during laser surface alloying. The thermodynamic parameters, ΔH{sub mix}, ΔS{sub mix}and δ as well as Δχ, should be used to predict the formation of the BCC solid solution, but they are not the strict criteria. Especially when Δχ reaches a high value (≥ 10%), BCC HEA will be partially decomposed, leading to the formation of (Co, Ni)Ti{sub 2} compound phases. - Highlights: •Preparing HEA coating on Ti-6Al-4V by laser surface alloying is successful. •The synthesized HEA coating mainly consists of BCC HEA and (Co, Ni)Ti{sub 2} compounds. •FIB technology was used to prepare the sample for TEM analysis. • ΔH{sub mix}, ΔS{sub mix}and δ as well as Δχ, should be all used to predict the formation of solid solution.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Electrochemical and microstructural characterization of magnetron-sputtered ATO thin films as Li–ion storage materials

Highlights: • Nano-structured ATO thin films prepared by RF magnetron sputtering at 25 °C, 100 °C and 200 °C, respectively. • ATO thin films show a high reversible capacity and high rate performance. • Electrochemical reaction mechanism of the ATO thin film was revealed by transmission electron microscopy. - Abstract: Sb-doped SnO{sub 2} (ATO) nanostructured thin films were prepared by using radio frequency magnetron sputtering at the substrate temperatures of 25 °C, 100 °C and 200 °C, respectively. All the ATO thin films have the similar redox characteristics in the cyclic voltammetry measurements. The ATO thin film sputtered at 200 °C shows the lowest charge transfer resistance and best electrochemical performance, and has a high reversible capacity of 679 mA h g{sup −1} at 100 mA g{sup −1} after 200 charge–discharge cycles and high rate performance of 483 mA h g{sup −1} at 800 mA g{sup −1}. The electrochemical mechanisms were investigated by analyzing the phase evolution of the ATO electrodes that had been electrochemically induced at various stages. The results reveal that the ATO underwent reversible lithiation/delithiation processes during the electrochemical cycles, i.e., the SnO{sub 2} reacted with Li{sup +} to produce metallic Sn and followed by the formation of the Li{sub x}Sn alloys during discharge process, and then Li{sub x}Sn alloys de-alloyed, Sn reacted with Li{sub 2}O, and even partially formed SnO{sub 2} during charge process.

36 MATERIALS SCIENCE↗
DOE OSTI2018

High-temperature deformation behavior and microstructural characterization of high-Mn bearing titanium-based alloy

Highlights: • The hot deformation behavior of a biomedical low-cost Ti-10Mn alloys was studied. • The flow curves of the alloy display periodic serrations attributed to dynamic strain aging. • Mn alloying increases the activation energy to 243 kJ/mol compared to pure Ti. • The dynamic recovery is more effective than dynamic recrystallization at hot deformation. - Abstract: Ti-Mn alloys exhibit an excellent potential for biomedical applications as well as structural engineering applications, especially in the aerospace industry. In order to control and enhance grain structure during the manufacturing of Ti-Mn alloys and thereby help to enhance mechanical properties such as strength and toughness, we studied the hot-deformation behavior of βTi-10Mn alloys. Isothermal compression tests were conducted in the strain rate range of 0.01–10 s{sup −1} and temperatures in the range of 850–1000 °C using a Gleeble thermomechanical simulator. High-temperature flow stress curves exhibited discontinuous yielding and pronounced periodic serrations without any strain hardening during compression straining of these alloys. Such peculiar behavior of this alloy is due to active dynamic strain aging in its β-bcc structure. Metallographic observations by electron-backscattered diffraction (EBSD) analysis revealed that dynamic recovery (DRV) is more active than continuous dynamic recrystallization (CDRX) when the alloy is deformed at high strain rates, i.e. higher than 1 s{sup −1}. Furthermore, the constitutive behavior of the alloy was modeled and the apparent hot-deformation activation energy of the alloy was estimated to be 243 kJ/mol, which is ~60% higher than the self-diffusion energy in pure titanium.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Change in equilibrium position of misfit dislocations at the GaN/sapphire interface by Si-ion implantation into sapphire—I. Microstructural characterization

Much research has been done to reduce dislocation densities for the growth of GaN on sapphire, but has paid little attention to the elastic behavior at the GaN/sapphire interface. In this study, we have examined effects of the addition of Si to a sapphire substrate on its elastic property and on the growth of GaN deposit. Si atoms are added to a c-plane sapphire substrate by ion implantation. The ion implantation results in scratches on the surface, and concomitantly, inhomogeneous distribution of Si. The scratch regions contain a higher concentration of Si than other regions of the sapphire substrate surface, high-temperature GaN being poorly grown there. However, high-temperature GaN is normally grown in the other regions. The GaN overlayer in the normally-grown regions is observed to have a lower TD density than the deposit on the bare sapphire substrate (with no Si accommodated). As compared with the film on an untreated, bare sapphire, the cathodoluminescence defect density decreases by 60 % for the GaN layer normally deposited on the Si-ion implanted sapphire. As confirmed by a strain mapping technique by transmission electron microscopy (geometric phase analysis), the addition of Si in the normally deposited regions forms a surface layer in the sapphire elastically more compliant than the GaN overlayer. The results suggest that the layer can largely absorb the misfit strain at the interface, which produces the overlayer with a lower defect density. Our results highlight a direct correlation between threading-dislocation density in GaN deposits and the elastic behavior at the GaN/sapphire interface, opening up a new pathway to reduce threading-dislocation density in GaN deposits.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Microstructural characterization and strengthening behavior of nanometer sized carbides in Ti–Mo microalloyed steels during continuous cooling process

Nanometer-sized carbides that precipitated in a Ti–Mo bearing steel after interrupted continuous cooling in a temperature range of 620–700 °C with or without hot deformation were investigated by field-emission-gun transmission electron microscopy. The nanometer-sized carbides were identified as randomly homogeneous precipitation carbides and interphase precipitation carbides coexisting in the ferrite matrix. It is found that this dual precipitation morphology of carbides in the steel leads to the non-uniform mechanical properties of individual ferrite grains. Vickers hardness data mainly revealed that, in the specimens cooled at a rate of 0.5 °C/s without hot deformation, the range of Vickers hardness distribution was 230–340 HV 0.1 when cooling was interrupted at 680 °C, and 220–360 HV 0.1 when cooling was interrupted at 650 °C. For the specimens cooled at a rate of 0.5 °C/s with hot deformation, the range of Vickers hardness distribution was 290–360 HV 0.1 when cooling was interrupted at 680 °C, and 280–340 HV 0.1 when cooling was interrupted at 650 °C. Therefore, a narrower range of hardness distribution occurred in the specimens that underwent hot deformation and were then cooled with a lower interrupted cooling temperature. The uniform precipitation status in each ferrite grain can lead to ferrite grains with a narrower Vickers hardness distribution. On the other hand, interrupted cooling produced a maximum Vickers hardness of 320–330 HV 0.1 for the hot deformed specimens and 290–310 HV 0.1 for the non-deformed specimens with cooling interrupted in the temperature range of 660–670 °C. The maximum Vickers hardness obtained in such a temperature range can be ascribed to the full precipitation of the microalloying elements in the supersaturated ferrite matrix with a tiny size (~ 4–7 nm). - Highlight: • The interrupted continuous cooling temperatures were 620 °C to 700 °C. • Precipitation carbides with dual dispersed morphology coexisted in the matrix. • Heavy hot deformation narrowed the range of hardness distribution. • Full precipitation of nano-sized carbides achieved maximum hardening.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Non-destructive Quantitative Phase Analysis and Microstructural Characterization of Zirconium Coated U-10Mo Fuel Foils via Neutron Diffraction

This report uses neutron diffraction to investigate the crystal phase composition of uranium-molybdenum alloy foils (U-10Mo) for the CONVERT MP-1 Reactor Conversion Project, and determines the effect on alpha-uranium contamination following the deposition of a Zr metal diffusion layer by various methods: plasma spray deposition of Zr powders at LANL and hot co-rolling with Zr foils at BWXT. In summary, there is minimal decomposition of the gamma phase U-10Mo foil to alpha phase contamination following both plasma spraying and hot co-rolling. The average unit cell volume, i.e. lattice spacing, of the Zr layer can be mathematically extracted from the diffraction data; co-rolled Zr matches well with literature values of bulk Zr, while plasma sprayed Zr shows a slight increase in the lattice spacing, indicative of interstitial oxygen in the lattice. Neutron diffraction is a beneficial alternative to conventional methods of phase composition, i.e. x ray diffraction (XRD) and destructive metallography. XRD has minimal penetration depth in high atomic number materials, particularly uranium, and can only probe the first few microns of the fuel plate; neutrons pass completely through the foil, allowing for bulk analysis of the foil composition and no issues with addition of cladding layers, as in the final, aluminum-clad reactor fuel plates. Destructive metallography requires skilled technicians, cutting of the foil into small sections, hazardous etching conditions, long polishing and microscopy times, etc.; the neutron diffraction system has an automated sample loader and can fit larger foils, so there is minimal analysis preparation; the total spectrum acquisition time is ~ 1 hour per sample. The neutron diffraction results are limited by spectra refinement/calculation times and the availability of the neutron beam source. In the case of LANSCE at Los Alamos, the beam operates ~50% of the year. Following the lessons learned from these preliminary results, optimizations to the process and analysis can be made, and neutron diffraction can become a viable and efficient technique for gamma/alpha phase composition determination for nuclear fuels.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2014

Mechanical and microstructural characterization of sulfonated pentablock copolymer membranes

ABSTRACT Creep experiments utilizing a membrane inflation geometry were used to characterize the mechanical properties of pentablock copolymer membranes designed for water purification applications. Membranes were formed by casting from micellar solutions, and structure development during the casting process was followed in real time with grazing incidence small angle X‐ray scattering. The thin film morphologies were consistent with previously published results obtained for much thicker solvent cast films. The biaxial creep compliance of the films for applied stresses in the megapascal range increased substantially as the degree of sulfonation and consequent hydration of the middle block was increased. The sulfonation level was much more important than the overall degree of ordering in determining the creep compliance of the hydrated membranes. © 2014 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2015 , 53 , 39–47

Laprade, Evan J.↗
DOE OSTI2017

High-Fidelity Microstructural Characterization and Performance Modeling of Aluminized Composite Propellant

Image processing and stereological techniques were used to characterize the heterogeneity of composite propellant and inform a predictive burn rate model. Composite propellant samples made up of ammonium perchlorate (AP), hydroxyl-terminated polybutadiene (HTPB), and aluminum (Al) were faced with an ion mill and imaged with a scanning electron microscope (SEM) and x-ray tomography (micro-CT). Properties of both the bulk and individual components of the composite propellant were determined from a variety of image processing tools. An algebraic model, based on the improved Beckstead-Derr-Price model developed by Cohen and Strand, was used to predict the steady-state burning of the aluminized composite propellant. In the presented model the presence of aluminum particles within the propellant was introduced. The thermal effects of aluminum particles are accounted for at the solid-gas propellant surface interface and aluminum combustion is considered in the gas phase using a single global reaction. In conclusion, properties derived from image processing were used directly as model inputs, leading to a sample-specific predictive combustion model.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Instance Segmentation for Direct Measurements of Satellites in Metal Powders and Automated Microstructural Characterization from Image Data

In this work, we propose instance segmentation as a useful tool for image analysis in materials science. Instance segmentation is an advanced technique in computer vision which generates individual segmentation masks for every object of interest that is recognized in an image. Using an out-of-the-box implementation of Mask R-CNN, instance segmentation is applied to images of metal powder particles produced through gas atomization. Leveraging transfer learning allows for the analysis to be conducted with a very small training set of labeled images. As well as providing another method for measuring the particle size distribution, we demonstrate the first direct measurements of the satellite content in powder samples. After analyzing the results for the labeled data dataset, the trained model was used to generate measurements for a much larger set of unlabeled images. The resulting particle size measurements showed reasonable agreement with laser scattering measurements. The satellite measurements were self-consistent and showed good agreement with the expected trends for different samples. Finally, we present a small case study showing how instance segmentation can be used to measure spheroidite content in the UltraHigh Carbon Steel DataBase, demonstrating the flexibility of the technique.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Experiments and modeling to characterize microstructure and hardness in 304L

Drawn 304L stainless steel tubing was subjected to 42 different annealing heat treatments with the goal of initializing a microstructural model to select a heat treatment to soften the tubing from a hardness of 305 Knoop to 225–275 Knoop. The amount of recrystallization and grain size caused by 18 heat treatments were analyzed via optical microscopy and image analysis, revealing the full range of recrystallization from 0 to 100%. The formation of carbides during the longer duration and higher-temperature heat treatments was monitored via transmission electron microscope evaluation. The experimental results informed a model which includes recovery, recrystallization, and grain growth to predict microstructure and hardness. After initialization of the model, it was able to predict hardness with a R 2 value of 0.95 and recrystallization with an R 2 value of 0.99. As a result, the model was then utilized in the design and testing of a heat treatment to soften the tubing.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Advanced Surface and Microstructural Characterization of Natural Graphite Anodes for Lithium Ion Batteries

Natural graphite powders were subjected to a series of thermal treatments in order to improve the anode irreversible capacity loss (ICL) and capacity retention during long-term cycling of lithium ion batteries. A baseline thermal treatment in inert Ar or N2 atmosphere was compared to cases with a proprietary additive to the furnace gas environment. This additive substantially altered the surface chemistry of the natural graphite powders and resulted in significantly improved long-term cycling performance of the lithium ion batteries over the commercial natural graphite baseline. Different heat-treatment temperatures were investigated ranging from 950-2900 C with the intent of achieving the desired long-term cycling performance with as low of a maximum temperature and thermal budget as possible. A detailed summary of the characterization data is also presented, which includes X-ray diffraction (XRD), X-ray photoelectron spectroscopy (XPS), Raman spectroscopy, and temperature-programed desorption mass spectroscopy (TPD-MS). This characterization data was correlated to the observed capacity fade improvements over the course of long-term cycling at high charge-discharge rates in full lithium-ion coin cells. It is believed that the long-term performance improvements are a result of forming a more stable solid electrolyte interface (SEI) layer on the anode graphite surfaces, which is directly related to the surface chemistry modifications imparted by the proprietary gas environment during thermal treatment.

Gallego, Nidia C↗
DOE OSTI2020

Microstructural characterization and assessment of mechanical properties of concrete based on combined elemental analysis techniques and Fast-Fourier transform-based simulations

This paper presents a pixel-based modeling approach of concrete which combines an experimental characterization of concrete and the Fast-Fourier transform simulations. High-resolution phase maps created from experimental characterization by micro X-ray fluorescence, energy dispersive X-ray analysis, and X-ray diffraction contain 9 different phases, including 22.17 vol.% of hydrated cement paste, 54.21 vol.% of minerals, and 23.62 vol.% of interfaces. These phases provide the input for determining the effective elastic properties, coupled with Fast-Fourier transform-based simulation. The simulation results show that the effective range of Young’s modulus of concrete is comparable with the range of experimental values ~ 37 ± 4 GPa with the assumption of realistic properties of interfaces.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Microstructural Characterization of High Burn-up Mixed Oxide Fast Reactor Fuel

High burn-up mixed oxide fuel with local burn-ups of 3.4–23.7% FIMA (fissions per initial metal atom) were destructively examined as part of a research project to understand the performance of oxide fuel at extreme burn-ups. Optical metallography of fuel cross-sections measured the fuel-to-cladding gap, clad thickness, and central void evolution in the samples. The fuel-to-cladding gap closed significantly in samples with burn-ups below 7–9% FIMA. Samples with burn-ups in excess of 7–9% FIMA had a reopening of the fuel-to-cladding gap and evidence of joint oxide-gain (JOG) formation. Signs of axial fuel migration to the top of the fuel column were observed in the fuel pin with a peak burn-up of 23.7% FIMA. Additionally, high burn-up structure (HBS) was observed in the two highest burn-up samples (23.7% and 21.3% FIMA). The HBS layers were found to be 3–5 times thicker than the layers found in typical LWR fuel. The results of the study indicate that formation of JOG and or HBS prevents any significant fuel-cladding mechanical interaction from occurring, thereby extending the potential life of the fuel elements.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗