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DOE OSTI2019

Microstructure evolution during near- T g annealing and its effect on shear banding in model alloys

By performing extensive molecular dynamics simulations, we investigate herein the deformation behavior in A l 90 S m 10 and C u 64.5 Z r 35.5 alloys after elongated isothermal annealing in the vicinity of the glass-transition temperature ( T g ). Different microstructural response to the annealing process was observed: A l 90 S m 10 maintains the glassy structure with improved energetic stability, enhanced short-range order (SRO), and a more pronounced spatial network that extends beyond the first atomic shell, while C u 64.5 Z r 35.5 forms nanocrystalline Laves C u 2 Zr phases. Shear banding occurs in both annealed systems under shear loading. For A l 90 S m 10 , the spatial network formed by the local clusters characterizing the SRO of the system is significantly weakened but remains appreciable in the shear band. In contrast, the crystalline ordering in the C u 64.5 Z r 35.5 is completely destroyed during shear banding. Consequently, while displaying higher yield strength, the annealed C u 64.5 Z r 35.5 sample appears to be less ductile. By carefully examining the effect of microstructures on the structural ordering in the shear band and the consequent mechanical response, our work contributes to a better understanding of the deformation mechanism of amorphous alloys as compared with that in crystalline materials.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Microstructural and rheological training and memory of nanocolloidal soft glasses under cyclic shear

An intrinsic feature of disordered and out-of-equilibrium materials, such as glasses, is the dependence of their properties on their history. An important example is rheological memory, in which disordered solids obtain properties based on their deformation history. Here, in this study, we employ x-ray photon correlation spectroscopy with in situ rheometry to characterize memory formation in a nanocolloidal soft glass due to cyclic shear. During a cycle, particles undergo irreversible displacements composed of a combination of shear-induced diffusion and heterogeneous, residual strain fields. At lower shear amplitudes, the displacements resemble a random walk in which the directions in each cycle are independent of those in preceding cycles, while at high amplitude, the irreversible displacements in consecutive cycles become correlated. The magnitudes of the displacements decrease with each cycle before reaching a steady state where the microstructure has been trained to achieve enhanced reversibility even at shear amplitudes well above yielding and despite the presence of thermal fluctuations. At amplitudes below and near yielding, these decreases are monotonic, while well above yielding, they are nonmonotonic, suggesting evidence of shear banding. Accompanying this microstructural training are corresponding decreases in the dissipation during each cycle and the magnitude of the residual stress toward steady-state values. Memory of the training is revealed by measurements in which the amplitude of the shear is changed after steady state is reached. The magnitude of the particle displacements, as well as the dissipation and the change in residual stress, vary nonmonotonically with the new shear amplitude, having minima near the training amplitude, thereby revealing correlated microscopic and macroscopic signatures of memory.

Chen, Yihao [Johns Hopkins Univ., Baltimore, MD (U↗

DOE OSTI2024

Investigation on laser absorption and x-ray radiation in microstructured titanium targets heated by short-pulse relativistic laser pulses

The enhancement effect of a microstructured surface on laser absorption and characteristic K α emission has been investigated by measuring K-shell emission from titanium (Ti) targets irradiated with high-intensity ( ∼ 10 20 W cm − 2 ), subpicosecond (500 fs) laser pulses. The experimental results indicate a modest enhancement ( 1.6 × ) of K α emission from microstructured targets compared to flat foils, but with a similar intensity and profile of He α and Li-like satellites. Particle-in-cell (PIC) simulations are implemented to further understand the underlying physical processes in the laser interaction with both targets, interpreting the mechanisms responsible for the K α enhancement. The reasons for the lower-than-expected enhancement of K α emission are discussed. The rapid heating of the bulk plasma might result in the premature shutdown of K α emission before the thermalization of hot electrons or even the end of laser pulses, suggesting that the use of K α emission as a diagnostic of the hot-electron yield or relaxation could lead to a misinterpretation. Published by the American Physical Society 2024

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2023

Microstructure-Property Relationships in Epitaxial Cu(In, Ga)Se2 Solar-Cell Absorbers

Epitaxially grown Cu(In,Ga)Se 2 (CIGS) absorber layers were analyzed by various techniques in scanning electron microscopy in order to reveal microstructure-property relationships in these thin films. Owing to their epitaxial nature, these CIGS absorber layers do not contain any grain boundaries, but only anti-phase domains (APDs) and dislocations. By combining electron channeling-contrast imaging, electron backscatter diffraction, and cathodoluminescence (CL), in some cases on identical specimen positions of polished cross-sections of CIGS/Mo/glass stacks, it was possible to correlate the presence and orientations of APDs and dislocations with the lateral distributions of the CL intensity and emission-peak energy. We studied CIGS layers with three different [Ga]/([Ga]+[In]) ratios as well as with and without NaF/KF treatments. Considerable differences between the CIGS layer properties in the microstructure-property relationships were found, depending on the growth parameters. Dislocations in the epitaxial CIGS layers do not tend to exhibit strong CL intensity decreases, which contrasts with the situation in numerous other semiconductor materials.

anti-phase domains↗

DOE OSTI2022

Steam oxidation and microstructural evolution of rare earth silicate environmental barrier coatings

A primary failure mode for environmental barrier coatings (EBCs) on SiC ceramic matrix composites (CMCs) is the oxidation of the intermediate Si-bond coating, where the formation of SiO 2 at the bond coating–EBC interface results in debonding and spallation. This work compares the microstructure evolution and steam oxidation kinetics of the Si-bond coating beneath yttrium/ytterbium disilicate ((Y/Yb)DS) and ytterbium disilicate/monosilicate (YbDS/YbMS) EBCs to better understand the impact of EBC composition on oxidation kinetics. After 500 1-h cycles at 1350°C, (Y/Yb)DS displayed a decreasing concentration of the monosilicate minor phase and increasing concentration of porosity as furnace cycling time increased, whereas the YbDS/YbMS EBC displayed negligible microstructural evolution. For both EBC systems, thermally grown oxide growth rates in steam were found to increase by approximately an order magnitude compared to dry air oxidation. The (Y/Yb)DS EBC displayed a reduced steam oxidation rate compared to YbDS/YbMS.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Microstructure and bonding between calcium aluminate cement‐containing gahnite–alumina matrix and refractory aggregates

Calcium aluminate cement enhances the thermomechanical properties of refractory castables through the formation of acicular calcium hexaluminate (CaO·6Al 2 O 3 ), Ca 2 Mg 2 Al 28 O 46 (CAM-I), and CaMg 2 Al 16 O 27 (CAM-II) phases in MgO- or MgAl 2 O 4 -containing castables. The compatibility of CA 6 with gahnite (ZnAl 2 O 4 ), and acicular Ca 2 Zn 2 Al 28 O 46 (CAZ-I) and CaZn 2 Al 16 O 27 (CAZ-II) phases formation have been previously reported. Here, in this work, the interaction between a CAC binder containing ZnAl 2 O 4 -Al 2 O 3 matrix with commonly used refractory aggregates such as tabular alumina (TA), alumina-rich (AR90, AR78) and stoichiometric (SM72) MgAl 2 O 4 spinels, and fused and dead-burned magnesia (FM, DBM, respectively) were investigated at 1650°C for 5 h. Microstructural analysis, using digital microscopy, scanning electron microscopy, and energy dispersive spectroscopy, revealed the formation of acicular CaZn 0.18 Al 11.82 O 18.91 , CAZ-I and CAZ-II grains, and strong interfacial bonding between the matrix and TA and spinel aggregates. FM and DBM were found to debond from the matrix. Thick interface layers were observed between the matrix and all the aggregates but TA. Null hypothesis significance testing (NHST) shows that the difference in the number of acicular grains between the interface zone and the bulk matrix (Z) is statistically significant for AR90/Z, SM72/Z, FM/Z, and DBM/Z interfaces, but not significant for TA/Z and AR78/Z. The role of the aggregates’ chemistry on the interfacial bonding and microstructure evolution is discussed.

Ramteke, Rajat Durgesh [Univ. of Alabama, Birmingh↗

DOE OSTI2021

Thermomechanical Microstructural Predictions of Fracture Nucleation of Zircaloy-4 Alloys With δ and ε Hydride Distributions

Abstract A crystalline dislocation-density formulation that was incorporated with a nonlinear finite-element (FE) method was utilized to understand and to predict the thermomechanical behavior of an hexagonal closest packed (h.c.p.) zircaloy system with hydrides with either face-centered cubic (f.c.c.) or body-centered cubic (b.c.c.) hydrides. This formulation was then used with a recently developed fracture methodology that is adapted for finite inelastic strains and multiphase crystalline systems to understand how different microstructurally based fracture modes nucleate and propagate. The interrelated microstructural characteristics of the different crystalline hydride and matrix phases with the necessary orientation relationships (ORs) have been represented, such that a detailed physical understanding of fracture nucleation and propagation can be predicted for the simultaneous thermomechanical failure modes of hydride populations and the matrix. The effects of volume fraction, morphology, crystalline structure, and orientation and distribution of the hydrides on simultaneous and multiple fracture modes were investigated for radial, circumferential, and mixed distributions. Another key aspect was accounting for temperatures changes due to the effects of thermal conduction and dissipated plastic work and their collective effects on fracture. For hydrided aggregates subjected to high temperatures, thermal softening resulted in higher ductility due to increased dislocation-density activity, which led to higher shear strain accumulation and inhibited crack nucleation and growth. The predictions provide validated insights into why circumferential hydrides are more fracture-resistant than radial hydrides for different volume fractions and thermomechanical loading conditions.

Engineering↗

DOE OSTI2019

Effect of Pre-Weld Heat Treatment on Microstructure and Creep Strength of ICHAZ in Grade 91 Steel

In this work, Grade 91 base metal was normalized with two different cooling conditions, water quenching and air cooling. The intercritical welding thermal cycle simulated by using the Gleeble system were applied to the heat-treated base metals to reproduce the intercritical heat-affected zone (ICHAZ). Microstructure, including precipitate and tempered martensite, of the base metal and ICHAZ was carefully characterized with advanced microscopy techniques. Creep strength of the simulated ICHAZs was evaluated at a high creep temperature of 650 °C with a stress of 100 MPa. A correlation between the microstructure and creep behavior of the ICHAZ is built to understand creep rupture mechanisms in the ICHAZ. The results show that more coarse carbides precipitated along the prior austenite grain boundaries after tempering in the water-quenched base metal. These carbides cannot be fully dissolved by the intercritical welding thermal cycle. The simulated ICHAZ generated from the water-quenched base metal underwent a higher grain recovery and growth during the typical post-weld heat treatment at 760 °C. Both simulated ICHAZs from two pre-weld heat treated base metals exhibit an extremely low creep resistance with a typical ductile fracture during creep testing. The faster grain growth and precipitate coarsening in the ICHAZ, simulated from the water-quenched base metal, made it even worse.

Wang, Yiyu↗

DOE OSTI2023

Surface Film Formation on Al-V Alloys with Far-From-Equilibrium Microstructure

Nanocrystalline supersaturated Al-V alloys produced by high-energy ball milling have been reported to exhibit enhanced corrosion resistance and mechanical properties compared to commercial Al alloys. Corrosion of passive alloys such as Al-V alloy relies on the characteristics of the surface film, which is studied using scanning/transmission electron microscopy and time-of-flight secondary ion mass spectrometry. The effect of microstructure and composition on the surface film has been investigated after different immersion periods (30 min, 2 h, and 1 day) in 0.1 M NaCl. The surface film was complex and composed of oxidized Al and V. The heterogeneous surface film was observed due to the presence of secondary phases and initiation of localized corrosion. The void formation was observed beneath the surface film that would potentially cause pitting corrosion. The generation of nano-sized voids was dependent on grain orientation. Compared to pure Al, the chloride penetration is suppressed in Al-V alloys. The effect of composition and microstructure on surface film formation and attendant corrosion behavior is discussed herein.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Understanding the Effect of Electrochemical Properties and Microstructure on the Microgalvanic Corrosion of Mg Alloys via Phase-Field Simulations

In this work, we apply a phase-field model to gain insights into the corrosion behavior of Mg alloys. Specifically, we study the effect of electrochemical properties of the materials and their environment and the spatial distribution of second phases in a magnesium alloy. To this end, we perform sensitivity analyses in which we separately vary the exchange current density and corrosion potential of the second phase, as well as the electrolyte conductivity. We describe the effects of these parameters on the corrosion current and the resulting corrosion-front morphology. We also confirm that the ratio between the Wagner length, calculated for the anodic phase, and the initial width of the anodic domain is a good predictor of the morphological characteristic of the corroding surface. In addition, we examine the effect of the microstructure on the corrosion behavior in both 2D and 3D systems by varying the shape, size, and distribution of the second-phase regions. Our findings provide insights into the influence of the two-phase microstructure on the corrosion behavior in a magnesium alloy.

Electrochemistry↗

DOE OSTI2019

Fundamental Relationship of Microstructure and Ionic Conductivity of Amorphous LLTO as Solid Electrolyte Material

All-solid-state Li-ion batteries (ASSLiB) attracted lots of attention mainly due to their higher safety compared with commercial Li-ion batteries. The research of solid electrolyte is critical for the development of ASSLiB, and among all the candidates of solid electrolyte materials, amorphous Lithium Lanthanum Titanate Oxide (LLTO) is promising because of its outstanding electrochemical stability up to 12V. However, the fundamental relationship among the ionic conductivity, microstructure, and mechanism of Li ion transport is still unrevealed. In this study, both amorphous LLTO thin film and LLTO powder were successfully prepared by sol-gel process. In order to determine the relationship between microstructure and ionic conductivity, various annealing time at 500°C were applied. This work shows that the ionic conductivity increases from 2.32 × 10 -8 S/cm to 9.01 × 10 -6 S/cm with the annealing time before LLTO starts to crystallize and decreases back to ~1.6 × 10 -9 S/cm after the formation of crystal phase. The absolute value of difference is close to 3 orders of magnitude. Furthermore, the morphology of the thin film changes accordingly, solvent evaporation, surface refinement and crystallization phases would occur sequentially, and this indicates that there is an optimal synthesis condition for the LLTO film. However, the changes of structure, morphology and ionic conductivity does not affect activation energy. This will help researchers to find optimized synthesis condition of amorphous LLTO and potentially search for and design other solid electrolyte materials.

25 ENERGY STORAGE↗

DOE OSTI2020

Kinetic Simulations of Microstructural Evolution (KSOME)

"Kinetic simulations of microstructural evolution" (KSOME) is an object Kinetic Monte Carlo (OMKC) simulation code. It is developed to simulate microstructural evolution in materials during irradiation. KSOME is developed from ground up with priority given to the flexibility, ease of upgradability, and computation efficiency, in that order. With previously developed simulation codes, various processes (more precisely, the diffusion-reaction processes) that can occur in a system were hardwired into the code. Hence, to perform higher fidelity simulations, a significant coding effort was required every time to incorporate either a more accurate description of existing processes or new processes. With KSOME, the necessity for frequent code upgrades whenever there is a need to perform higher fidelity simulations is either eliminated or reduced significantly. In KSOME, the categories of various diffusion-reaction processes and the data-management system are hardwired, while the execution of the diffusion-reaction processes specific to a system is specified via input files. In the present version of KSOME, the analytical expression required to calculate defect interaction radii are inputted via a text file. However, the ability to parse mathematical expressions from a text file can be extended to input the analytical expression to calculate other defect properties; including the expressions to calculate the change in the migration barriers of mobile defects due to long-range interaction with extended defects

Nandipati, Giridhar [Pacific Northwest National La↗

DOE OSTI2025

Laser Powder Bed Fusion Microstructure Surrogate Model

SAND2025-11467O The Laser Powder Bed Fusion (LPBF) Microstructure Surrogate Model is a machine-learning-based tool. It predicts statistics of microstructures that are produced by the LPBF additive manufacturing process. It includes a series of codes for training, testing, and analyzing the model as well as utility scripts for handling data. Sandia National Laboratories is a multimission laboratory managed and operated by National Technology & Engineering Solutions of Sandia, LLC, a wholly owned subsidiary of Honeywell International Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525.

Moser, Daniel [Sandia National Lab. (SNL-CA), Live↗

DOE OSTI2019

Dissipation of radiation energy in concentrated solid-solution alloys: Unique defect properties and microstructural evolution

The effort to develop metallic alloys with increased structural strength and improved radiation performance has focused on the incorporation of either solute elements or microstructural inhomogeneities to mitigate damage. The recent discovery and development of single-phase concentrated solid-solution alloys (SP-CSAs) has prompted fundamental questions that challenge established theories and models currently applicable to conventional alloys. Here, the current understanding of electronic and atomic effects, defect evolution, and microstructure progression suggests that radiation energy dissipates in SP-CSAs at different interaction strengths via energy carriers (electrons, phonons, and magnons). Modification of electronic- and atomic-level heterogeneities and tailoring of atomic transport processes can be realized through tuning of the chemical complexity of SP-CSAs by the selection of appropriate elements and their concentrations. Fundamental understanding of controlling energy dissipation via site-to-site chemical complexity reveals new design principles for predictive discovery and guided synthesis of new alloys with targeted functionalities, including radiation tolerance.

36 MATERIALS SCIENCE↗

DOE OSTI2023

3-D reconstruction and microstructural characterization of neutron-irradiated U-10Zr fuel using FIB-SEM serial sectioning

Herein, focused ion beam-scanning electron microscopy serial sectioning was applied to characterize the three-dimensional (3-D) porosity and phase regions of a neutron-irradiated U-10 wt% Zr fuel. The specimen was removed from an intermediate radial region of a fuel pin irradiated to 5.7 at.% burn-up. Backscattered electron imaging and energy-dispersive spectroscopy were performed on each serial section, allowing for the characterization of microstructural morphology and composition. Porosity size followed a lognormal distribution, ranging from 1.46 × 10 –4 to 25.58 µm 3 with a total porosity volume fraction of 13.02%. Distinctive microstructural regions were identified by composition and porosity: (1) a Zr-rich region with an average composition of 28.4 wt% Zr and a local porosity fraction of 6.88%, and (2) a U-rich region with an average composition of 97.0 wt% U and a local porosity fraction of 14.11%; subdivided into U-rich—high porosity (16.68%) and U-rich—low porosity (8.04%) regions. The detailed 3-D compositional and porosity regions can improve nuclear fuel performance codes.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

FFT-based model for irradiated aggregate microstructures in concrete

The concrete biological shield of light water reactors is exposed to neutron and gamma irradiation throughout its lifetime, which results in the long-term degradation of the concrete’s mechanical properties. Under neutron irradiation, the concrete’s aggregates are subjected to radiation-induced volumetric expansion (RIVE), which strongly depends on the mineral content of the aggregate and exhibits the largest expansion in silicate-bearing minerals. In this work, the authors used the fast Fourier transform-based code Microstructure-Oriented Scientific Analysis of Irradiated Concrete (MOSAIC) in 2D to model the expansion of five different aggregates provided by the Japan Concrete Aging Management Program (JCAMP). Comparable rock specimens were irradiated at the JEEP-II test reactor. The model uses realistic aggregate microstructure reconstruction based on high-resolution characterization images. The model accounts for anisotropic RIVE, thermal expansion, and the associated initiation and propagation of damage. The RIVE models are calibrated based on expansion data in the literature. The authors assume that damage occurs exclusively at interfaces between the particles that compose an aggregate and that these interfaces also exhibit swelling. Using a micromechanical model, the evolution of Young’s modulus with RIVE is calculated for each aggregate and compared with Russian irradiation data. The modeled linear expansion agrees well with the experimentally measured expansion. Furthermore, the model also predicts that anisotropic RIVE and thermal expansion result in an earlier onset of damage with neutron fluence than in the isotropic case.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Microstructure development in a cold worked SRF Nb sheet undergoing 700°C-900°C/3h heat treatments.

Bulk Nb for TESLA shaped SRF cavities is a mature technology, with high gradient (>35 MV/m) and high Q cavities (>1010, ~2K) routinely fabricated. Significant advances are in order to push Q?s to 1011 (~2K), and involve modifications to the sub-surface Nb layers by impurity doping (N, O). In order to achieve the lowest surface resistance any trapped flux needs to be expelled for cavities to reach high Q?s. There is clear evidence that cavities fabricated from polycrystalline sheets meeting current specifications require higher temperatures beyond 800oC leads to better flux expulsion, and hence improves Q. Recently, cavities fabricated with a non-traditional Nb sheet with initial cold work due to cold rolling expelled flux better after 800°C/3h heat treatment than cavities fabricated using fine-grain polycrystalline Nb sheets. Here, we analyze the microstructure development in Nb from the vendor supplied cold work non-annealed sheet that was fabricated into an SRF cavity as a function of heat treatment building upon the methodology development to analyze microstructure being developed by the FSU-MSU-UT-Austin- JLAB collaboration. The results indicate correlation between full recrystallization and better flux expulsion.

Balachandran, S.↗

DOE OSTI2017

Enhancing Electrophoretic Display Lifetime: Thiol-Polybutadiene Evaporation Barrier Property Response to Network Microstructure

An evaporation barrier is required to enhance the lifetime of electrophoretic deposition (EPD) displays. As EPD functions on the basis of reversible deposition and resuspension of colloids suspended in a solvent, evaporation of the solvent ultimately leads to device failure. Incorporation of a thiol-polybutadiene elastomer into EPD displays enabled display lifetime surpassing six months in counting and catalyzed rigid display transition into a flexible package. Final flexible display transition to mass production compels an electronic-ink approach to encapsulate display suspension within an elastomer shell. Final thiol-polybutadiene photosensitive resin network microstructure was idealized to be dense, homogeneous, and expose an elastic response to deformation. Research at hand details an approach to understanding microstructural change within display elastomers. Polybutadiene-based resin properties are modified via polymer chain structure, with and without added aromatic urethane methacrylate difunctionality, and in measuring network response to variation in thiol and initiator concentration. Dynamic mechanical analysis results signify that cross-linked segments within a difunctionalized polybutadiene network were on average eight times more elastically active than that of linked segments within a non-functionalized polybutadiene network. Difunctionalized polybutadiene samples also showed a 2.5 times greater maximum elastic modulus than non-functionalized samples. Hybrid polymer composed of both polybutadiene chains encompassed TE-2000 stiffness and B-1000 elasticity for use in encapsulating display suspension. Later experiments measured kinetic and rheological response due to alteration in dithiol cross-linker chain length via real time Fourier transform infrared spectroscopy and real-time dynamic rheology. Distinct differences were discovered between dithiol resin systems, as maximum thiol conversion achieved in short and long chain length dithiols was 86% and 11%, respectively. Oscillatory real-time rheological experiments confirmed a more uniform network to better dissipate applied shear in short chain length dithiol systems, as long chain length dithiols relayed a steep internal stress build-up due to less cross-links and chain entanglements. Thorough understanding of network formation aids the production of a stronger and impermeable elastomeric barrier for preservation of EPD displays.

36 MATERIALS SCIENCE↗