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All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

High Volume Production of Nanoscale Elements

The utility of nanoscale elements spans numerous potential markets including healthcare, communications, energy, optics, and structures. The energy market in particular will require large volumes and is price sensitive. In this talk we will discuss strategies to scale nanoscale elements, including nanoparticle inks and nanoscale thin films, for the large area deposition (hundreds of square meters) using high through put processes. Historically, roll-to-roll production of thin films has been carried out at very high speeds over large areas using solution phase inks. Nanoparticles are produced in a bottom-up approach in solution phase that simplifies the processing and is amenable to ink formulations. Sintering and annealing of the thin films can be increased by using radiation thermal processing that integrates easily into roll-to-roll manufacturing. Results of printed films on the order of tens of nanometers to hundreds of nanometers are presented including studies of morphologies and uniformity over large areas. Solar cells devices using the roll-to-roll setup are demonstrated and a techno-economic analysis of the manufacturing is proposed. These results are presented with a comparison to the current photovoltaic technologies in production.

Druffel, Thad↗
DOE OSTI2021

The Effect of Homogenization Heat Treatment on the Texture Evolution in U-10Mo Alloy

Uranium alloyed with 10 wt% Mo (U-10Mo) undergoes discontinuous precipitation (DP) when subjected to sub-eutectoid heat-treatment. It is hypothesized that the crystallographic texture of the U-10Mo can be modified to minimize the degree of DP, however the evolution of texture throughout the manufacturing process is not well understood. Crystallographic textures of two U-10Mo samples homogenized at 900°C and 1000°C were studied after uniaxial rolling and annealing. A total of 6 samples were analyzed upon rolling using a combination of hot and cold rolling conditions to strains of 83%, 90% and 97% and subsequently annealed at 700°C for one hour. Microstructures and textures were analyzed via electron backscatter diffraction (EBSD) for each homogenization, strain and post-annealed states. Results show that the U-10Mo exhibits typical rolling textures seen in body-centered cubic materials with increasing intensities of both a- and ?-fibers with increasing strain. After recrystallization, the texture appeared to be effectively randomized in all samples. Homogenization temperature showed no effect on the rolling and recrystallization behavior. Potential factors leading to the randomization of texture are discussed along with the implications of textures on the minimization of DP.

nuclear fuel, texture, rolling↗
DOE OSTI2018

Effect of Wear on Surface Crack Propagation in Rail–Wheel Wet Contact

The interaction between wear and rolling contact fatigue in wet contact was investigated by means of experiments on a two-disk test bench. Specimens of various railway wheel steels were coupled with specimens of the same rail steel, subjected to rolling and sliding wet contact with varying sliding/rolling ratio. Some tests with a dry rolling–sliding contact phase preceding wet contact were carried out as well (dry–wet tests). The pressurization of the fluid entrapped in the surface cracks was the cause of a rapid and severe damage in the dry–wet tests, due to the nucleation of surface cracks by ratcheting in the dry phase, which subsequently propagate in the wet phase. In the wet tests, the fluid pressurization effect was much mitigated due to the absence of initial surface cracks; the specimens subjected to higher sliding/rolling ratio showed the best performance against rolling contact fatigue, due to the effect of wear in reducing the length of surface cracks. A model for assessing the interaction between wear and rolling contact fatigue was proposed, based on the correction of the classical Paris law for crack propagation by taking into account the effect of wear on crack length reduction. The application of the model to the experimental tests allowed finding a correlation between the model predictions and the occurrence of fatigue failure.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Influence of Local Inhomogeneity of Thermomechanical Treatment Conditions on Microstructure Evolution in Aluminum Alloys

The influence of local inhomogeneity of the stress–strain condition on structure and texture evolution during thermomechanical treatment of aluminum alloys is studied in this work. For this purpose, laboratory rolling and plane strain tests that simulated roughing mill thermomechanical modes were performed. For all processes, the local inhomogeneity of structure evolution was estimated. For this purpose, x-ray texture analysis, EBSD and optical microscopy were used. Additionally, the calculations which allow to evaluate local inhomogeneity of stress–strain conditions for the each process were performed. The experimental results were compared with mathematical simulation output. They indicated structure and texture evolution inhomogeneities, especially during the plane strain and industrial rolling processes. In the plane strain test, typical local deformation zones occurred with different resulting grain size and texture effects than those observed in both rolling processes. This difference was mainly associated with different stress states, strain intensity and strain rate distribution throughout the deformation zone. This study demonstrated that the inhomogeneity of these parameters has a strong impact on structure and texture evolution in the first stage of thermomechanical treatment. In the center layer, laboratory rolling could adequately generate the structure and texture effects observed during rolling of ingots in a commercial mill. Plane strain tests can generate useful results only in the case of adequate choice of sample geometry.

36 MATERIALS SCIENCE↗
DOE OSTI2019

The Evolution of Deformation-Induced Carbides during Divorced Eutectoid Transformation in GCr15 Steels

A series of rolling experiments were carried out using GCr15 steel to investigate the effect of initial microstructure on the spheroidizing process, and especially the effect of deformation-induced carbides (DIC) on the divorced eutectoid transformation (DET). The results indicated that the existence of DIC was beneficial to the spheroidizing process, the optimal initial microstructure for DET was lamellar pearlite, and DIC precipitated at grain boundaries. The average thickness of the cementite lamella and the size of DIC decreased with a decrease in rolling temperature in the critical temperature region. When the specimen was rolled at 1053 K, a small amount of DIC of size ~ 1 μm precipitated at grain boundaries. In contrast, the amount of DIC was increased when the rolling temperature was decreased to 1023 K, whereas the size of DIC was reduced to ~ 0.5 μm. Interrupted quenching experiments indicated that DIC (M{sub 7}C{sub 3}) were transformed to M{sub 3}C during the process of partial austenitization, and the evolution of spheroidization was influenced by the variation in the initial microstructure. For the specimens rolled at 1023 K, only ~ 60 min was needed to achieve the dissolution of DIC, which was the minimum, and the total time needed to achieve spheroidization was reduced to ~ 90 min.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Microstructure, texture evolution and magnetic properties of strip-casting non-oriented 6.5 wt.% Si electrical steel doped with cerium

A 0.3 mm thick non-oriented 6.5 wt.% Si electrical steel sheet doped with cerium is produced by twin-roll strip casting, hot rolling, warm rolling and annealing. A detailed study of the cerium precipitates in the as-cast strip, microstructure and texture evolution at different processing stages is carried out by electron probe micro-analysis, optical microscopy, X-ray diffraction and electron backscattered diffraction analysis. Grain interior distributing precipitates identified as Ce-oxides, Ce-oxysulfides and Ce-phosphides, and boundary distributing Ce-oxides and Ce-phosphides are observed in the as-cast strip. The initial as-cast strip is characterized by a much finer solidification microstructure and dominated by obvious < 001 >//ND texture through the strip thickness. After hot and warm rolling, inhomogeneous microstructure containing large amounts of in-grain shear bands is characterized by mixed < 110 >//RD and < 111 >//ND textures. The texture of the annealed sheet with a relatively large average grain size is far more optimized by the domination of the beneficial cube, rotated cube, (001)< 120 > to (001)< 130 > and Goss texture components, and the elimination of the detrimental γ-fiber texture, leading to a superior magnetic induction and improved iron loss. - Highlights: • An Fe–6.5 wt.% Si as-cast strip doped with cerium was produced. • A thin warm rolled sheet with limited edge cracks was obtained. • Microstructure and texture evolution at each stage were investigated. • Strong λ-fiber and Goss recrystallization textures were formed. • The magnetic properties of the annealed sheet were significantly improved.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Annealing texture of nanostructured IF steel

In the present work, the evolution of annealing texture in nanostructured interstitial free steel fabricated via accumulative roll bonding (ARB) process was investigated. Textural evolution after post-annealing of ARB-processed samples was evaluated using X-ray diffraction. There were several texture transitions in the γ-fiber and ζ-fiber during ARB and post-annealing treatment. It was found that with increasing the number of ARB cycles, the volume fraction of the low angle grain boundary decreased and the high angle grain boundary fraction increased. Also, the shear texture was dominant after the first cycle, while for other samples, the rolling texture was dominant. The one-cycle sample clearly indicated a weak α-fiber and γ-fiber and a relatively strong ζ-fiber. In addition, during the recrystallization and before the grain growth, the intensity of α-fiber and γ-fiber decreased, the intensity of ζ-fiber increased, and the intensity of (011)〈100〉 orientation in the ε-fiber and η-fiber increased. Moreover, it was concluded that the transition from the rolling texture to the shear one was a sign of occurrence of the recrystallization (before the grain growth). Finally, with increasing the number of ARB cycles, the intensity of rolling and shear textures saturated and a stable texture formed. - Highlights: • There were texture transitions in the γ-fiber and ζ-fiber. • When the number of cycles increased, the low angle grain boundaries decreased. • The shear texture was dominant after the first cycle. • Transition from rolling texture to shear one was a sign of recrystallization. • With increasing the number of ARB cycles, a stable texture formed.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Microstructure and texture evolution of duplex stainless steels with different molybdenum contents

Highlights: • The 3.05Mo steel has higher resistance to strain-induced transformation than the 0.28Mo steel. • The increased Mo content affects the grain growth of austenite and ferrite due to the effects of segregation and anchoring. • At high annealing temperatures, this Mo retarding effect is weakened. • The suppression of γ-fiber development in the ferrite texture is associated with the increased Mo content. • High amounts of Mo generate unfavorable conditions for the formation of CSL boundaries. - Abstract: The microstructure and texture evolution of duplex stainless steels with different molybdenum contents were studied. For this purpose, hot-rolled 2205 and 2304 samples were solution-annealed at 1100 °C for 1800 s and then cold-rolled to a 75% thickness reduction. This was followed by an isothermal annealing at 900 and 1100 °C for 180 s. The EBSD technique was used to determine the phase ratio, crystallographic texture, and microstructural characteristics. The hot-rolled steel had a work hardened microstructure and the samples submitted to intermediate annealing presented mainly deformation-free grains. Cold rolling resulted in a substantial reduction in the phase spacing with the formation of the strain-induced α′-martensite (SIM) from the metastable austenite. After annealing at 900 °C, the ferrite grains retained the elongated shape of the cold-rolled condition and the primary recrystallization progressed in the austenite phase. Increasing the Mo content increased the resistance to strain-induced martensitic transformation and inhibited the grain growth of austenite phase during annealing at 900 °C. Increasing annealing temperature to 1100 °C promoted the coarsening of both bcc and fcc structures with the formation of annealing twins in the austenitic grains. The recrystallization kinetics and subsequent grain growth occur earlier in ferrite than in austenite phase. Differences in Mo content did not significantly alter the evolution of austenite texture, whereas in the ferrite phase the increase in Mo content suppressed the γ-fiber development. Oriented nucleation was the predominant mechanism observed during the recrystallization of ferritic grains in the 2205 samples. The development of ∑19a boundaries was associated with the selected growth of {554}<225>{sub α} grains in the annealed 2304 samples. Annealing twins were associated with the formation of Σ3 boundaries after the heat treatments. Grain coarsening resulted in a larger fraction of the special boundaries in ferrite phase but inhibited the CSL formation in the austenite phase.

36 MATERIALS SCIENCE↗
NASA NTRS1933

The Effects of Slots and Flaps on Lateral Control of a Low-wing Monoplane as Determined in Flight

This paper presents the results of flight tests made to determine the effect of slots and flaps on the lateral control of a low-wing monoplane. Maximum angular accelerations in roll and yaw produced by sudden application of the ailerons and maximum accelerations in yaw produced by sudden application of the rudder during gliding flight were recorded for the following wing arrangements: (a) no auxiliary device; (b) full-span slots; (c) plain flaps; (d) flaps and full-span slots; (e) wing-tip slots. Rolling- and yawing-moment coefficients were derived from the accelerations. The full span slots and the flaps each had about the same influence on the aileron rolling moments. At values of the lift coefficient obtainable with the plain wing, the effect of these devices was negligible. At the higher lift coefficients obtainable with these devices, the rolling-moment coefficients increased slightly but, despite this increase, the aileron effectiveness progressively decreased with increasing lift coefficient, owing to the corresponding reduction in air speed. In the range covered by the tests, the effectiveness of the controls was appreciably reduced by the wing-tip slots. The adverse yawing moment of the ailerons experienced at the large lift coefficients obtained with the flaps was appreciably less than at similar lift coefficients obtained with either full-span or wing-tip slots. The yawing moments produced by the rudder were only slightly affected by the use of the auxiliary devices. The airplane was found to be laterally unstable with all combinations tested. Because of the angular velocities acquired in the time taken to deflect the ailerons the rolling moments recorded in flight were only about two thirds the values that would have been obtained with the wing restrained as in wind-tunnel tests.

WING SLOTS↗
DOE OSTI2019

Hardening of A6111-T4 Aluminum Alloy at Large Strains and Its Effect on Sheet Forming Operations

In a number of sheet metal stamping and joining processes, the material undergoes large plastic deformation exceeding the range of plastic strain achievable in a standard tensile test prior to material plastic instability. In order to extend the range of effective strains, the multistep rolling process was employed which enabled prestraining of aluminum sheet above 2.0 of true strain. Tensile testing of rolled samples was used to identify the flow stress corresponding to the level of prestrain: By varying the prestrain level, several data points were obtained for the studied flow curve. The numerical simulation using Abaqus software for the cold rolling process of aluminum strips confirmed that majority of the strip is deformed in plane strain compression condition. Performed simulation of the LDH test determined that earlier fracture might occur if the curve obtained via rolling–tensile testing approach is used versus traditional power law approximation and Voce law approximation. The results of simulation for the multistep drawing of a cylindrical cup revealed possible wrinkling in the die entry area during redrawing stage of the process if the rolling–tensile testing flow curve is employed.

36 MATERIALS SCIENCE↗
DOE OSTI2019

AZ61 and AZ61-La Alloys as Anodes for Mg-Air Battery

AZ61 and AZ61-0.5La (wt.%) alloys are prepared by the conventional casting method and then, AZ61 and AZ61-0.5La alloy sheets are obtained with multi-pass hot rolling. Microstructures and electrochemical properties of four alloys are investigated, and discharge properties are tested by an assembled Mg-air battery using alloy anode sheets with a dimension of 70 × 100 × 2.5 mm. Results show that Al{sub 11}La{sub 3} phases are formed in as-cast AZ61-0.5La alloy and promote the grain refinement and the formation of uniform microstructure in as-rolled AZ61-0.5La alloy. As-rolled AZ61-0.5La alloy exhibits a weak self-corrosion tendency but a strong discharge activity. After discharge test for 5 h, the Mg-air battery based on the as-rolled AZ61-0.5La sheet can provide the maximum power output of 1.625 W, and as-rolled AZ61-0.5La anode can supply the maximum energy density of 1417 mWhg{sup −1}. In addition, the relationship between microstructures and discharge properties is sufficiently described and discussed in this paper.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Deformation Strengthening of Uranium and Dilute Uranium Alloys

The strength and ductility of uranium and dilute uranium alloys can be substantially improved by deformation strengthening. The yield strength of unalloyed uranium can be nearly doubled by rolling in the vicinity of 250°C. The embrittling effect of hydrogen is also overcome, eliminating the need for vacuum outgassing to obtain good ductility. Significant differences in longitudinal versus transverse tensile properties result, in part, from texture introduced by unidirectional rolling. Warm rolling of U-2.3%Nb results in both traditional strain hardening and a significant Bauschinger effect, resulting in differences between tensile and compressive yield strength. A similar combination of strain hardening and Bauschinger effect also occurs in deformation strengthened U-0.75%Ti. Warm rolling of U-0.75%Ti results in significantly better combinations of tensile yield strength and ductility than can be obtained by conventional age hardening. Warm rolling prior to aging also reduces the loss of ductility which typically accompanies conventional age hardening. Here, an approach is developed in which the effects of prior deformation on tensile and compressive yield strengths are analyzed in terms of texture, long-range dislocation, and Bauschinger effects. The Bauschinger effect is shown to vary in sign with the type of deformation, thus providing opportunities to tailor tensile and compressive properties.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

Reconfigurable Vanadium Dioxide Nanomembranes and Microtubes with Controllable Phase Transition Temperatures

Here, two additional structural forms, free-standing nanomembranes and microtubes, are reported and added to the vanadium dioxide (VO 2 ) material family. Free-standing VO 2 nanomembranes were fabricated by precisely thinning as-grown VO 2 thin films and etching away the sacrificial layer underneath. VO 2 microtubes with a range of controllable diameters were rolled-up from the VO 2 nanomembranes. When a VO 2 nanomembrane is rolled-up into a microtubular structure, a significant compressive strain is generated and accommodated therein, which decreases the phase transition temperature of the VO 2 material. The magnitude of the compressive strain is determined by the curvature of the VO 2 microtube, which can be rationally and accurately designed by controlling the tube diameter during the rolling-up fabrication process. The VO 2 microtube rolling-up process presents a novel way to controllably tune the phase transition temperature of VO 2 materials over a wide range toward practical applications. Furthermore, the rolling-up process is reversible. A VO 2 microtube can be transformed back into a nanomembrane by introducing an external strain. Because of its tunable phase transition temperature and reversible shape transformation, the VO 2 nanomembrane-microtube structure is promising for device applications. As an example application, a tubular microactuator device with low driving energy but large displacement is demonstrated at various triggering temperatures.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2014

Just enough inflation: power spectrum modifications at large scales

We show that models of 'just enough' inflation, where the slow-roll evolution lasted only 50- 60 e-foldings, feature modifications of the CMB power spectrum at large angular scales. We perform a systematic analytic analysis in the limit of a sudden transition between any possible non-slow-roll background evolution and the final stage of slow-roll inflation. We find a high degree of universality since most common backgrounds like fast-roll evolution, matter or radiation-dominance give rise to a power loss at large angular scales and a peak together with an oscillatory behaviour at scales around the value of the Hubble parameter at the beginning of slow-roll inflation. Depending on the value of the equation of state parameter, different pre-inflationary epochs lead instead to an enhancement of power at low ℓ, and so seem disfavoured by recent observational hints for a lack of CMB power at ℓ∼< 40. We also comment on the importance of initial conditions and the possibility to have multiple pre-inflationary stages.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2016

Constraints on single-field inflation

Many alternatives to canonical slow-roll inflation have been proposed over the years, one of the main motivations being to have a model, capable of generating observable values of non-Gaussianity. In this work, we (re-)explore the physical implications of a great majority of such models within a single, effective field theory framework (including novel models with large non-Gaussianity discussed for the first time below). The constraints we apply — both theoretical and experimental — are found to be rather robust, determined to a great extent by just three parameters: the coefficients of the quadratic EFT operators (δN){sup 2} and δNδE, and the slow-roll parameter ε. This allows to significantly limit the majority of single-field alternatives to canonical slow-roll inflation. While the existing data still leaves some room for most of the considered models, the situation would change dramatically if the current upper limit on the tensor-to-scalar ratio decreased down to r<10{sup −2}. Apart from inflationary models driven by plateau-like potentials, the single-field model that would have a chance of surviving this bound is the recently proposed slow-roll inflation with weakly-broken galileon symmetry. In contrast to canonical slow-roll inflation, the latter model can support r<10{sup −2} even if driven by a convex potential, as well as generate observable values for the amplitude of non-Gaussianity.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2026

Engineering Microstructure in Dry-Processed Cathodes Via Calendering

Calendering serves as a multifunctional step in dry electrode processing that not only densifies the electrode but also induces polytetrafluoroethylene (PTFE) fibrillation and reorganizes the microstructure. These coupled effects are essential for achieving electrical connectivity and sufficient cohesion, yet they also introduce trade-offs, such as active material particle fracture, pore collapse, and excessive porosity loss, that can hinder ionic transport. This research systematically maps the calendering parameter space for LiNi0.6Mn0.2Co0.2O2 (NMC622) dry cathodes with a target thickness of ∼100 µm and porosity of ∼30% by varying roll gaps, roll temperature, roll speed, and the number of passes. A practical processing window for this formulation and electrode architecture is identified that achieves sufficient PTFE fibrillation and strong interfacial contact while minimizing particle fracture and preserving the porosity required for efficient ionic transport. In particular, gradual-gap calendering with moderate per-pass compression mitigates fracture and pore collapse while still reaching the target thickness with reasonable throughput, and slower roll speeds with modest roll temperatures further reduce mechanical damage. These results provide actionable guidance for scaling NMC622-based thick dry-processed cathodes.

Park, Hyunji↗
DOE OSTI2015

SU-E-J-46: Evaluation of the Accuracy of a Six Degree of Freedom Robotic Couch Using ConeBeam CT Images of the Isocal Phantom

Purpose The accuracy of Varian PerfectPitch six degree of freedom (DOF) robotic couch was examined using Varian Isocal phantom and cone-beam CT (CBCT) system. Methods CBCT images of the Isocal phantom were taken at different pitch and roll angles. The pitch and roll angles were varied from 357 to 3 degrees in one degree increments by input from service console, generating a total of 49 combinations with couch angle (yaw) zero. The center positions of the 16 tungsten carbide BBs contained in the Isocal were determined with in-house image processing software. Expected BBs positions at different rotation angles were determined mathematically by applying a combined translation/rotation operator to BB positions at zero pitch and roll values. A least square method was used to minimize the difference between the expected BB positions and their measured positions. In this way rotation angles were obtained and compared with input values from the console. Results A total of 49 CBCT images with voxel sizes 0.51 mm × 0.51 mm × 1 mm were used in analysis. Among the 49 calculations, the maximum rotation angle differences were 0.1 degree, 0.15 degree, and 0.09 degree, for pitch, roll, and couch rotation, respectively. The mean ± standard-deviation angle differences were 0.028±0.001 degree, −0.043±0.003 degree, and −0.009±0.001 degree, for pitch, roll, and couch rotation, respectively. The maximum isocenter shifts were 0.3 mm, 0.5 mm, 0.4 mm in x, y, z direction respectively following IEC6127 convention. The mean isocenter shifts were 0.07±0.02 mm, −0.05±0.06 mm, and −0.12±0.02 mm in x, y and z directions. Conclusion The accuracy of the Varian PerfectPitch six DOF couch was studied with CBCTs of the Isocal phantom. The rotational errors were less than 0.15 degree and isocenter shifts were less than 0.5 mm in any direction. This accuracy is sufficient for stereotactic radiotherapy clinical applications.

60 APPLIED LIFE SCIENCES↗