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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

CAN IBEX DETECT INTERSTELLAR NEUTRAL HELIUM OR OXYGEN FROM ANTI-RAM DIRECTIONS?

To better constrain the parameters of the interstellar neutral flow, we searched the Interstellar Boundary EXplorer (IBEX)-Lo database for helium and oxygen from the interstellar medium in the anti-ram direction in the three years (2009–2011) with the lowest background rates. We found that IBEX-Lo cannot observe interstellar helium from the anti-ram direction because the helium energy is too low for indirect detection by sputtering off the IBEX-Lo conversion surface. Our results show that this sputtering process has a low energy threshold between 25 and 30 eV, whereas the energy of the incident helium is only 10 eV for these observations. Interstellar oxygen, on the other hand, could in principle be detected in the anti-ram hemisphere, but the expected magnitude of the signal is close to the detection limit imposed by counting statistics and by the magnetospheric foreground.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2014

SU-E-T-148: Efficient Verification Method for Modulated Electron Radiotherapy Treatment Plans

Purpose: For shallow tumors, modulated electron radiotherapy (MERT) promises a reduction of dose to distal organs at risk. At our institution a framework was developed in order to create treatment plans for MERT employing both forward and inverse optimization. In this work, an efficient quality assurance (QA) process is established. Methods: Treatment plans for three different tumor sites were created using an inverse optimization. These plans consist of 6–12 segments and energies between 6 and 18 MeV. An already established QA process for photon IMRT plans is now extended to additionally handle MERT plans. First, the dose distributions are calculated in a homogenous water phantom. For this task a dedicated Monte Carlo (MC) framework for MERT is used. Second, the segments are applied on a stand-alone amorphous silicon electronic portal imaging device (EPID) using a source-to-surface distance of 70 cm. This device was calibrated for electron beams in a previous work. An in-house developed analysis software, is then utilized for comparisons and evaluation of the measured and calculated dose distributions. Results: For all three plans the calculated dose distributions agree well with the measured ones. Using a 2D gamma comparison (2% of dose max/2 mm and 10% dose threshold) passing rates >98% are achieved.The dose calculation for each plan on the water phantom, using voxels of 0.2×0.2×0.2 cm{sup 3}, takes at maximum 30 min on a single core Pentium 2.66 GHz system with 6 GB RAM, to reach a statistical uncertainty of 2% (1 std. dev.). Conclusion: An already established QA procedure for IMRT photon plans was applied for MERT. The dedicated MC framework and the use of EPID measurements allow an efficient QA procedure in a clinical environment. This work was supported by Varian Medical Systems.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2017

Efficacy of atmospheric pressure dielectric barrier discharge for inactivating airborne pathogens

Atmospheric pressure plasmas have gained attention in recent years for several environmental applications. This technology could potentially be used to deactivate airborne microorganisms, surface-bound microorganisms, and biofilms. Here, the authors explore the efficacy of the atmospheric pressure dielectric barrier discharge (DBD) to inactivate airborne Staphylococcus epidermidis and Aspergillus niger that are opportunistic pathogens associated with nosocomial infections. This technology uses air as the source of gas and does not require any process gas such as helium, argon, nitrogen, or hydrogen. Moreover, the effect of DBD was studied on aerosolized S. epidermidis and aerosolized A. niger spores via scanning electron microscopy (SEM). The morphology observed on the SEM micrographs showed deformations in the cellular structure of both microorganisms. Cell structure damage upon interaction with the DBD suggests leakage of vital cellular materials, which is a key mechanism for microbial inactivation. The chemical structure of the cell surface of S. epidermidis was also analyzed by near edge x-ray absorption fine structure spectroscopy before and after DBD exposure. Our results from surface analysis revealed that reactive oxygen species from the DBD discharge contributed to alterations on the chemistry of the cell membrane/cell wall of S. epidermidis.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2015

Gap Analysis to Support Modeling the Long-Term Degradation of Used Nuclear Fuel Canisters

Welded stainless steel canisters are being used worldwide for dry storage of used nuclear fuel (UNF) assemblies, and the number of canisters in use is steadily increasing. In support of work currently being pursued at Pacific Northwest National Laboratory to understand the atmospheric corrosion behavior of spent fuel dry storage systems, a gap analysis is underway to assess the state of knowledge for modeling of the long-term degradation of a UNF canister. The fundamental aim of this work is to inform research and development (R&D) efforts to establish a sound technical basis to support the extended dry storage of UNF for 100+ years. The analysis is considering all major components of the atmosphere corrosion degradation processes, ranging from contaminant sources and climatic interactions to regional conditions of particle transport and deposition, to microscale effects leading to stress corrosion cracking. The results of this gap analysis will be used to define the R&D pathway to develop an integrated multi-scale atmospheric corrosion modeling capability for UNF in dry storage canisters that can support the safe and reliable performance of these structures for more than 100 years.

Nuclear Fuel Canisters↗
DOE OSTI2021

Topology optimization of additively manufactured fluidic components free of internal support structures

This report integrates projection-based approaches for implementing overhang constraints with fluid topology optimization to design additively manufactured fluidic components that do not require internal support structures. Internal support structures are challenging, potentially impossible to remove in complex fluid networks, yet would degrade fluidic performance if left within the part. This presents a major challenge in coupling topology optimization with additive manufacturing in the design of fluid components. The proposed approach leverages past work in overhang constraints for solid mechanics, including projection formulations and adjoint sensitivity analysis, and considers incompressible Navier–Stokes equations for laminar fluid flow. The approach is demonstrated on 2D and 3D fluid topology optimization problems to minimize pressure drop and constrain mass flow rates in pipes and manifolds. Resulting designs are crisp, logical, satisfy performance constraints, and satisfy overhang constraints, eliminating the need for internal support structures.

42 ENGINEERING↗
DOE OSTI2024

Geological Thermal Energy Storage (GeoTES) Charged with Solar Thermal Technology Using Depleted Oil/Gas Reservoirs and Carnot-Battery Technique Using Shallow Reservoirs: Preprint

Geological thermal energy storage (GeoTES) utilizes the underground reservoirs to storage and dispatch energy per given demand schedule over a time scale up to seasons of a year. The energy input can be of various sources/forms; in this paper, we investigate 1) the GeoTES technology with solar thermal hybridization and using depleted oil/gas reservoirs; 2) the GeoTES technology with heat pumps charged by excess renewable electricity and using low-temperature shallow reservoirs. For each GeoTES technology, we carry out the suitability analysis of candidate reservoirs, develop initial techno-economic models, and validate the model with selected case study. The paper provides an overview of our technical progress on the topics of concern and aims to promote a wider acceptance of the GeoTES technologies in the future energy market.

Carnot battery↗
DOE OSTI2022

IER 488: MUSiC Accomplishments and Goals [Slides]

IER-488: Measurement of Uranium Subcritical and Critical (MUSiC) consists of measurements of bare, HEU systems covering a large range of reactivities. Multiple detector systems and analysis methods are being used to obtain detector-independent results. Massive amounts of data and information available. Substantial analysis has been completed for both critical and subcritical configurations. Work in progress is largely novel research and will result in several conference proceedings, journal publications, and a subcritical benchmark. There is still a large amount of data that has not been analyzed and much more to come from the analysis of the Measurements of Uranium Subcritical and Critical.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2021

Site Ambient Temperatures and Operating Schedules for EIC - Utility CW Considerations

The heat dissipated by the EIC accelerator system and components is ultimately removed by the conventional water-cooling systems that will be ultimately dissipated the waste heat to the atmosphere. An estimated 45 MW of heat will be dissipated to water during full beam operation and that will need to be effectively rejected to the atmosphere. Approximately 50% of the heat is required to be rejected to a low temperature heat sink that cannot be achieved by an evaporative cooling tower during summer. To operate during these summer months, a secondary chilled water refrigeration system will be required that would increase the cost of the cooling water system. Further, operating chiller compressor in the summer months will increase the energy consumption of the machine. This analysis is being prepared to evaluate the impact on operating and capital costs on the cooling system for various summer operating schedules while utilizing the most cost-effective scenario of an evaporative cooling system. The technology selection for the various heat sinks is addressed in a separate write-up and are not expected to change the conclusions of this write-up.

43 PARTICLE ACCELERATORS↗
DOE OSTI2019

Thermal and Thermoelectric Phenomena in Novel Naterials and Systems of Disordered and Interacting Electrons

The major goals of this project were: 1. To study thermal transport in systems of disordered electrons in the presence of the long-range Coulomb interaction, 2. To combine the Quantum Kinetic Equation approach with the Renormalization Group analysis of disordered interacting electrons for studying thermal transport near the Metal Insulator Transition, 3. To study thermal transport and thermopower in systems of disordered electrons in the presence of strong electron-electron collisions at intermediate temperatures, and 4. To study the effects of out of plane vibrations on the thermal transport in graphene.

36 MATERIALS SCIENCE↗
DOE OSTI2013

A novel Whole Air Sample Profiler (WASP) for the quantification of volatile organic compounds in the boundary layer

The emission and fate of reactive VOCs is of inherent interest to those studying chemical biosphere-atmosphere interactions. In-canopy VOC observations are obtainable using tower-based samplers, but the lack of suitable sampling systems for the full boundary 5 layer has limited the data characterizing the vertical structure of such gases above the canopy height and still in the boundary layer. This is the important region where many reactive VOCs are oxidized or otherwise removed. Here we describe an airborne sampling system designed to collect a vertical profile of air into a 3/800 OD tube 150m in length. The inlet ram air pressure is used to flow sampled air through the 10 tube, which results in a varying flow rate based on aircraft speed and altitude. Since aircraft velocity decreases during ascent, it is necessary to account for the variable flow rate into the tube. This is accomplished using a reference gas that is pulsed into the air stream so that the precise altitude of the collected air can be reconstructed post-collection. The pulsed injections are also used to determine any significant effect 15 from diffusion/mixing within the sampling tube, either during collection or subsequent extraction for gas analysis. This system has been successfully deployed, and we show some measured vertical profiles of isoprene and its oxidation products methacrolein and methyl vinyl ketone from a mixed canopy near Columbia, Missouri.

Mak, J. E.↗
DOE OSTI2017

File format for normalizing radiological concentration exposure rate and dose rate data for the effects of radioactive decay and weathering processes

This report specifies the electronic file format that was agreed upon to be used as the file format for normalized radiological data produced by the software tool developed under this TI project. The NA-84 Technology Integration (TI) Program project (SNL17-CM-635, Normalizing Radiological Data for Analysis and Integration into Models) investigators held a teleconference on December 7, 2017 to discuss the tasks to be completed under the TI program project. During this teleconference, the TI project investigators determined that the comma-separated values (CSV) file format is the most suitable file format for the normalized radiological data that will be outputted from the normalizing tool developed under this TI project. The CSV file format was selected because it provides the requisite flexibility to manage different types of radiological data (i.e., activity concentration, exposure rate, dose rate) from other sources [e.g., Radiological Assessment and Monitoring System (RAMS), Aerial Measuring System (AMS), Monitoring and Sampling). The CSV file format also is suitable for the file format of the normalized radiological data because this normalized data can then be ingested by other software [e.g., RAMS, Visual Sampling Plan (VSP)] used by the NA-84’s Consequence Management Program.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2026

Cradle-to-Grave Lifecycle Analysis of U.S. Medium- and Heavy-Duty Vehicle-Fuel Pathways: A Greenhouse Gas Emissions Assessment of Current (2021) and Future (2035) Technologies

This study presents a cradle-to-grave lifecycle analysis of energy use and greenhouse gas (GHG) emissions for U.S. medium- and heavy-duty vehicles across current (2021) and future (2035) technologies using the Greenhouse gas, Regulated Emissions, and Energy use in Technologies (GREET) model with industry-vetted assumptions. Results vary across vehicle classes but point to common trends: today, battery electric vehicles (BEVs) offer significant (10–60%) GHG emissions reduction compared to diesel internal combustion engine vehicles and are the lowest emissions option per ton-mile of cargo movement, followed by hydrogen fuel cell electric vehicles (FCEVs) (5–50% emissions reduction). Emissions savings depend largely on the duty cycle and fuel economy of the vehicle type. Future vehicle technology advancements result in comparable emission reductions associated with BEVs and hydrogen FCEVs. Weight-limited BEV trucks see less per-ton-mile emissions reduction due to the impact of battery weight on increased vehicle weight and reduced payload capacity. By 2035, improvements in vehicle efficiency can reduce emissions across all powertrains. However, very low levels of emissions require switching vehicles’ use-phase fuel/energy to low-carbon fuels and electricity. Renewable diesel, e-fuels, hydrogen produced from natural gas with carbon capture and storage or renewables, and use of low-carbon electricity can all achieve over 70% reduction in GHG emissions from the current day diesel-based internal combustion engine vehicle.

alternative fuels↗
DOE OSTI2025

The AGORA High-Resolution Galaxy Simulations Comparison Project

Context. Satellite galaxies experience multiple physical processes when interacting with their host halos, often leading to the quenching of star formation. In the Local Group, satellite quenching has been shown to be highly efficient, affecting nearly all satellites except the most massive ones. While recent surveys study Milky Way-analogs to assess how representative our Local Group is, the dominant physical mechanisms behind satellite quenching in Milky Way-mass halos remain under debate. Aims. We analyze satellite quenching within the same Milky Way-mass halo simulated using various widely used astrophysical codes, each using different hydrodynamic methods and implementing different supernovae feedback recipes. The goal is to determine whether quenched fractions, quenching timescales, and the dominant quenching mechanisms are consistent across codes or if they show sensitivity to the specific hydrodynamic method and supernovae feedback physics employed. Methods. We used a subset of high-resolution cosmological zoom-in simulations of a Milky Way-mass halo from the multiple-code AGORA CosmoRun suite. Our analysis focuses on comparing satellite quenching across the different models and against observational data. We also analyzed the dominant mechanisms driving satellite quenching in each model. Results. We find that the quenched fraction is consistent with the latest SAGA Survey results within its 1σ host-to-host scatter across all the models. Regarding quenching timescales, all the models reproduce the trend observed in the ELVES survey, Local Group observations, and previous simulations: The less massive the satellite, the shorter its quenching timescale. All of our models converge on the dominant quenching mechanisms: Strangulation halts cold gas accretion in all satellites, while ram pressure stripping is the predominant mechanism for gas removal, and it is particularly effective in satellites with M * <10 8 M ⊙ . Nevertheless, the efficiency of the stripping mechanisms differs among the codes, showing a strong sensitivity to the different supernovae feedback implementations and/or hydrodynamic methods employed.

Local Group↗
DOE OSTI2017

OmegaWINGS: The First Complete Census of Post-starburst Galaxies in Clusters in the Local Universe

Galaxies that abruptly interrupt their star formation in <1.5 Gyr present recognizable features in their spectra (no emission and Hδ in absorption) and are called post-starburst (PSB) galaxies. By studying their stellar population properties and their location within the clusters, we obtain valuable insights on the physical processes responsible for star formation quenching. We present the first complete characterization of PSB galaxies in clusters at 0.04<z<0.07, based on WINGS and OmegaWINGS data, and contrast their properties to those of passive (PAS) and emission-line (EML) galaxies. For V<20, PSBs represent 7.2 ± 0.2% of cluster galaxies within 1.2 virial radii. Their incidence slightly increases from the outskirts toward the cluster center and from the least toward the most luminous and massive clusters, defined in terms of X-ray luminosity and velocity dispersion. The phase-space analysis and velocity-dispersion profile suggest that PSBs represent a combination of galaxies with different accretion histories. Moreover, PSBs with the strongest Hδ are consistent with being recently accreted. PSBs have stellar masses, magnitudes, colors, and morphologies intermediate between PAS and EML galaxies, typical of a population in transition from being star-forming to passive. Comparing the fraction of PSBs to the fraction of galaxies in transition on longer timescales, we estimate that the short-timescale star formation quenching channel contributes two times more than the long timescale one to the growth of the passive population. Processes like ram-pressure stripping and galaxy–galaxy interactions are more efficient than strangulation in affecting star formation.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2020

AGC-4 Experiment Irradiation Monitoring Data Qualification Final Report

The Graphite Technology Development Program ran a series of six experiments to quantify the effects of irradiation on nuclear grade graphite. This report focuses on the fourth experiment, Advanced Graphite Creep 4 (AGC 4). The Advanced Reactor Development (ARD) Technology Development Office (TDO) Program for research and development activities require documentation of qualified monitoring data to design and license the first high-temperature reactor nuclear plant. Qualified data meets the requirements for use as described in the experiment planning and quality assurance documents. Failed data do not meet the requirements and provide no useable information. Trend data may not meet all requirements but still provide some useable information. Use of Trend data requires assessment of how any deficiencies affect a particular use of the data. AGC-4 began with Advanced Test Reactor (ATR) Cycle 157D on May 30, 2015. After irradiating the graphite for two cycles, the capsule was removed from the reactor after ATR Cycle 158A, which ended on January 2, 2016, due to interference with another experiment. Irradiation was resumed with Cycle 162A on October 7, 2017 after the interfering experiment was removed from the reactor. AGC-4 irradiation completed by the end of Cycle 166B on January 10, 2020. Between Cycles 162A and 166B, AGC-4 capsule was removed from the reactor core during two Powered Axial Locator Mechanism (PALM) Cycles 163A and 165A to avoid overheating. All thermocouples (TCs) have functioned throughout the AGC-4 experiment. A total of 9,256,184 out of all 11,167,213 temperature records (or 82.9%) are Qualified for use by the ARD Program and 1,911,029 missing values are Failed. Argon, helium, and total gas flow data were within expected ranges, except only eight out-of-range values occurred during outages. A total of 21,240,627 out of all 22,288,5103 gas flow rates (or 92.8%) are Qualified for use by the ARD Program and 1,644,476 are Failed records mostly due to missing values. Discharge gas line moisture values were consistently low during full ATR power, except for 162B, when moisture content was increasing to more than 200 ppmv by the end of this cycle. During outages, moisture content reached as high as 700 ppmv. 1,089,941 out of a total of 1,107,331 moisture values (or 98.4%) are within the measurement range of the instrument and are Qualified for use by the ARD Program and 17,390 missing moisture values are Failed. Graphite creep specimens were subjected to one of three loads: 393, 491, or 589 lbf. For a brief period during Cycle 157D between 12:19 on June 2, 2015, and 08:23 on June 11, 2015, the load cells were wired incorrectly, resulting in missing stack load data. Missing stack loads were estimated from measured ram pressures using regression equations developed from the existing data from Cycle 157D. Estimated stack loads during this period are considered to be an accurate representation of actual load applied to the stacks. These loads deviate slightly from the planned loads. This deviation does not prevent the data from being Qualified for use but must be taken into account when analyzing the effect of load on creep. 6,095,728 out of a total of 6,403,985 moisture values (or 95.2%) are within the measurement range of the instrument and are Qualified for use by the ARD Program and 308,257 missing load values are Failed. Stack displacement increased consistently throughout the eight cycles, with total displacement reached highest value of 2.4 in by the end of irradiation. During ATR outages, a set of pneumatic rams raised the stacks of graphite creep specimens to ensure the specimens were not stuck within the test train. This stack raising was performed seven times throughout irradiation. All stacks were raised successfully each time. 4,744,974 out of a total of 6,094,513 displacement values (or 77.9%) are within the measurement range of the instrument and are Qualified for use by the ARD Program and 1,349,539 displacement values are Failed mostly due to missing values. Analyses were conducted on correlations between TCs to look for trends and step changes that might indicate instrument degradation or failure. Correlation analysis was used to identify instances when TCs form short circuits, referred to as virtual junctions, which result in TCs reporting temperatures from some location in the capsule other than the location where they were intended to read. No evidence of virtual junctions was found. Analyses were also conducted on control charts of temperature differences of between two TCs, which are expected to behave consistently throughout the entire irradiation period. Upward or downward trend over time indicates at least one TC in the pair was drifted. Examining control charts for all 66 possible pairs out of twelve TCs installed in the AGC-4 capsules reveal no clear drift failures occurred, except unstable behavior of two TCs in Zone 3, TC-7 and TC-8, over irradiation time. In conclus

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Deployment of neural-network-based neutron microscopic cross sections in the Griffin reactor physics application

The capability to utilize neural networks to predict macroscopic and microscopic cross section parametric spaces has been developed for the Griffin reactor physics application. The LibTorch interface enables Griffin's MOOSE-based materials to interact with LibTorch-trained models, allowing for the evaluation of complex macroscopic or microscopic cross section spaces, which are then used to evaluate the neutronic properties of the Griffin finite element model. This study benchmarks traditional ISOXML-formatted tabulation libraries against neural network-based models for 279 nuclides on 20,160 grid points for zero-dimensional and two-dimensional reactor models. Benchmark metrics include the fundamental mode eigenvalue, fission and absorption rates, and various temperature coefficients of reactivity (isothermal, fuel, and moderator). From the perspective of storage space, the complete set of LibTorch models uses 11 MB on disk, compared to the 10 GB for the ISOXML multigroup library that covers the same grid space. For the two-dimensional performance case considered in Griffin, the Torch model uses 97% less RAM than the reference ISOXML dataset while runtime increases by a factor of 3 when using the LibTorch model compared to the ISOXML dataset with multi-linear interpolation. The LibTorch model consistently yields errors within 0.01% for most analyzed quantities except for the temperature coefficients of reactivity where the maximum discrepancies are up to 0.3 $\frac{pcm}{K}$. Due to the neural network attempting to best predict quantities with no regard for a positive or negative bias for any given quantity, predictions may experience random fluctuations, resulting in both positive and negative errors. Future work will entail both depletion and coupled transient analysis to determine the predictive capabilities of Griffin with neural network-based cross sections.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2016

AGC-4 Experiment Irradiation Monitoring Data Qualification Interim Report

The Graphite Technology Development Program is running a series of six experiments to quantify the effects of irradiation on nuclear grade graphite. The fourth experiment, Advanced Graphite Creep 4 (AGC 4), began with Advanced Test Reactor (ATR) cycle 157D on May 30, 2015, and has been irradiated for two cycles. The capsule was removed from the reactor after ATR cycle 158A, which ended on January 2, 2016, due to interference with another experiment. Irradiation will resume when the interfering experiment is removed from the reactor. This report documents qualification of AGC 4 experiment irradiation monitoring data for use by the Advanced Reactor Technologies (ART) Technology Development Office (TDO) Program for research and development activities required to design and license the first HTR nuclear plant. Qualified data meet the requirements for use as described in the experiment planning and quality assurance documents. Failed data do not meet the requirements and provide no useable information. Trend data may not meet all requirements, but still provide some useable information. Use of Trend data requires assessment of how any deficiencies affect a particular use of the data. All thermocouples (TCs) have functioned throughout the AGC-4 experiment. All temperature data are Qualified for use by the ART TDO Program. Argon, helium, and total gas flow data were within expected ranges and are Qualified for use by the ART TDO Program. Discharge gas line moisture values were consistently low during cycle 157D. At the start of cycle 158A, gas moisture briefly spiked to over 600 ppmv and then declined throughout the cycle. Moisture values are within the measurement range of the instrument and are Qualified for use by the ART TDO Program. Graphite creep specimens were subjected to one of three loads, 393, 491, or 589 lbf. For a brief period during cycle 157D between 12:19 on June 2, 2015 and 08:23 on June 11, 2015 the load cells were wired incorrectly resulting in missing stack load data. Missing stack loads were estimated from measured ram pressures using regression equations developed from the existing data from cycle 157D. Estimated stack loads during this period are considered to be an accurate representation of actual load applied to the stacks. These loads deviate slightly from the planned loads. This deviation does not prevent the data from being Qualified for use, but must be taken into account when analyzing the effect of load on creep. Stack displacement increased consistently throughout the first two cycles with total displacement ranging from 0.4 to 0.8 in. During ATR outages, a set of pneumatic rams raised the stacks of graphite creep specimens to ensure the specimens were not stuck within the test train. This stack raising was performed twice. All stacks were raised successfully each time. The load and displacement data are Qualified for use by the ART TDO Program.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Magnesium Alloy ZK60 Tubing made by Shear Assisted Processing and Extrusion (ShAPE)

ZK60 Magnesium tubing has been friction extruded from as-cast billets and T5 conditioned bars using Shear Assisted Processing and Extrusion (ShAPE). Tubes having an outer diameter of 50.8 mm and wall thickness of 1.9 mm were extruded with >20 times less ram force compared to conventional extrusion due to the unique shearing conditions and tooling inherent to ShAPE. Microstructures of the as-cast billet and T5 bar feedstock materials were significantly different from each other in terms of grain size, texture, and second phase distribution; yet the resulting microstructures after ShAPE were remarkably similar. An average grain size of 4-5 microns, 20o tilt of basal texture away from the extrusion axis, and refined second phases having a uniform distribution were achieved independent of the feedstock material. Hardness for as-extruded and artificially aged tubes are presented with isotropic behavior explained by detailed microstructural analysis. This work suggests that bulk ZK60 magnesium alloys extrusions may be fabricated in a single step, with microstructures that are unobtainable with conventional extrusion.

Friction Stir Extrusion, Friction Consolidation an↗