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At least 1,549 records · Page 86
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Effect of Heat Treatment on Microstructure Evolution and Mechanical Properties of Selective Laser Melted Inconel 718 Alloy

The microstructure characteristics of the selective laser melted Inconel 718 alloy under as-deposited, homogenization + solution + aging (HSA) and solution + aging (SA) conditions were studied. The anisotropy and heterogeneity of mechanical properties under different conditions were also investigated. Under the as-deposited condition, the morphology and size of the grains are heterogeneous. The dendrite structures which grow nearly perpendicular to the molten pool traces, accompanying interdendritic Laves phase, can be observed within the grains. The dendrite structure completely disappeared, and the Laves phases embedded in the interdendritic regions also dissolved into the matrix to precipitate γ′ and γ″ phases after heat treatments. Fully recrystallized grains were obtained under the HSA condition, while only incomplete recrystallized grains were obtained under the SA condition. However, the characteristics of γ′ and γ″ phases are very similar under the HSA and SA conditions. Significant improvement in strength after heat treatments was due to the dissolution of undesirable Laves phase and the precipitation of γ′ and γ″ phases. For all the three conditions, different tensile properties were observed depending on the orientation of the specimens. The scatter of mechanical properties is notable, and heat treatments increased the scatter of mechanical properties.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Corrosion Behavior of Fe-7Cr-1Mo-12Zr Metal Waste Form Alloy in Simulated Repository Environment

Metal waste forms (MWF) are solid metallic waste categorized as high-level radioactive waste generated during pyro-reprocessing of spent metallic fuels and geologically disposed off. This waste form generated requires an excellent corrosion resistance in a geological repository environment. In the present work, Fe-7Cr-1Mo-12Zr MWF alloy was developed by casting in an arc melting furnace. The x-ray diffraction analysis revealed the formation of stable phases of α-Fe solid solution and the intermetallic phases of Fe{sub 2}Zr and Fe{sub 23}Zr{sub 6}. The corrosion behavior of Fe-7Cr-1Mo-12Zr alloy was investigated using electrochemical techniques in aggressive (highly acidic with Cl{sup −}) and nominal repository pH environment. Cyclic potentiodynamic polarization studies indicated the shift in corrosion potential toward cathodic potential in highly acidic solution with Cl{sup −}. The corrosion mechanism of pitting is associated with acidified pH medium with more Cl{sup −}, whereas uniform corrosion or transpassive dissolution is resultant of mild acidity or mild alkaline medium. The passive region is wider in pH 5 and 8 when compared to pH 1 and 3. Electrochemical impedance spectroscopic (EIS) analysis revealed the lowering of passive film stability in the highly acidic medium in the presence of Cl{sup −}. The role of passive oxide layers on the corrosion resistance of the Fe-7Cr-1Mo-12Zr MWF alloy is discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Characterization of Hydrophobic Silane Film Deposited on AISI 304 Stainless Steel for Corrosion Protection

This present study was conducted to determine the aptitude of hydrophobic silane coating in corrosion resistance of AISI 304 stainless steel substrate at the nanoscale. Three newly developed hydrophobic silane-based compounds of compositions, namely [tris(trimethylsiloxy)silyethyl]dimethylchlorosilane (alkyl); tridecafloro-1,1,2,2-tetrahydrooctyltrichlorosilane (FOTS); and henicosyl-1,1,2,2-tetrahydrododecyltricholrosilane (FDDTS), were used as precursors to coat AISI 304 stainless steel surfaces. Prior to deposition, the substrate surfaces were pretreated with plasma oxide via a multi-step treatment to serve as adhesion. The plasma oxide and the silane precursors were deposited by using a hybrid atomic layer deposition and chemical vapor deposition process. The structural, chemical and electrochemical stabilities were investigated using SEM, AFM, XRD, ATR-FTIR, potentiodynamic polarization and electrochemical impedance spectroscopy (EIS). The results showed that the microstructures and morphology of the coated samples were similar, due to the chlorosilane functionalization. The FTIR indicated complete hydrolysis at the nanoscale while the polarization results showed that nano-coating can hamper the corrosion propagation mechanisms. Furthermore, the EIS results revealed that all the precursors acted as a barrier to AISI 304 dissolution into the electrolyte. The electrochemical effect was observed in the microstructural transformation of the coatings. Although all the precursors were shown to have been effective at few nanoscales, the stability of the FDDTS showed to have superseded that of alkyl and FOTS.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Solutionizing Time on Improving the Microstructure and Mechanical Properties of Aged AZ80 Mg Alloy

The effects of solutionizing soak time and aging on the microstructure and mechanical properties of cast AZ80 Mg alloy were investigated. Optical microscopy, scanning electron microscopy and x-ray diffraction revealed the dissolution of β-Mg{sub 17}Al{sub 12} phase in the solution-treated samples which was later detected in the aged condition. Solution treatments at 420 °C for 4-16 h with water quenching followed by aging at 200 °C for 10 h were carried out, causing discontinuous precipitates to be formed with different precipitate morphologies at the various soak times. The discontinuous precipitates were observed to transform from the interdendritic segregation to parallel lamellae with increasing soak time to 8-10 h. As the soak time increased to 16 h, parallel lamellae transformed into tree-like precipitate morphology. The results showed significant changes in the interlamellar spacing at different soak times, and such precipitate morphology could influence the microstructure and mechanical properties after the aging process. A good combination of strength and ductility was obtained when the cast AZ80 Mg alloy was solution-treated at 420 °C for 10 h and aged at 200 °C for 10 h. Compared to the as-cast condition, a significant increase in ultimate tensile strength (50%), yield strength (47%) and elongation (43%) were observed.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Niobium on the Secondary Precipitates and Tempering Resistance of Spray-Formed M3:2 High-Speed Steel

The precipitation of secondary carbides in spray-formed M3:2 high-speed steels with or without 2% niobium (Nb) addition during overtempering at 600 °C was characterized, and the carbides were identified in detail using transmission electron microscopy. Strengthening in the peak-hardened state is due to coherent precipitates of types MC and M{sub 2}C. During overtempering, the hardness of M3:2 steel greatly decreases due to M{sub 2}C coarsening with the precipitation of M{sub 3}C carbide, whereas the very fine and dense nature of the M{sub 2}C precipitates is responsible for the remarkable long-time strength exhibited by the Nb-containing steel. The MC precipitates, however, are fairly stable. The addition of Nb results in substantial dissolution of Mo and Cr into the matrix prior to tempering, which refines the secondary M{sub 2}C precipitate dispersion and delays overaging reactions; therefore, superior tempering resistance can be obtained.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Anomalous Annealing Response of Directed Energy Deposited Type 304L Austenitic Stainless Steel

Directed energy deposited (DED) and forged austenitic stainless steels possess dissimilar microstructures but can exhibit similar mechanical properties. In this study, annealing was used to evolve the microstructure of both conventional wrought and DED type 304L austenitic stainless steels, and significant differences were observed. In particular, the density of geometrically necessary dislocations and hardness were used to probe the evolution of the microstructure and properties. Forged type 304L exhibited the expected decrease in measured dislocation density and hardness as a function of annealing temperature. Here, the more complex microstructure–property relationship observed in the DED type 304L material is attributed to compositional heterogeneities in the solidification microstructure.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Integrated Simulation Framework for Additively Manufactured Ti-6Al-4V: Melt Pool Dynamics, Microstructure, Solid-State Phase Transformation, and Microelastic Response

In this work, to accelerate the establishment of fundamental understanding of the additive manufacturing (AM) process and its influence on microstructural evolution and related properties, we develop a multiphysics and multiscale modeling framework that integrates: (1) a high-fidelity powder-scale three-dimensional simulation of transient heat transfer and melt flow dynamics, (2) cellular automaton simulation of solidification grain structure and texture, (3) phase-field modeling of precipitation and dissolution of second-phase precipitate during repeated thermal cycles, and (4) microstructure-based micro- and mesoscopic elastic response calculation. Using Ti-6Al-4V as a model system, we demonstrate the application of the integrated framework to simulate complex microstructure evolution during a single-track laser powder bed fusion process and the associated mechanical response. Our modeling framework successfully captures the solidification β grain structure as a function of laser power and scanning speed, α precipitation upon subsequent cooling with different rates, and elastic response of the resulting (α + β) two-phase microstructure. The key features of solidification and second-phase precipitate microstructures, and their dependence on processing parameters, agree well with existing experimental observations. Finally, the established modeling framework is generally applicable to other metallic materials fabricated by AM.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Enhancing Surface Finish of Additively Manufactured 316L Stainless Steel with Pulse/Pulse Reverse Electropolishing

To improve the reliable integration of additively manufactured (AM) metal components, there is an urgent need for surface finishing methods capable of processing rough, “as-printed” surfaces. Here, we present a new and scalable electropolishing (EP) technique for use on AM 316L stainless steel (SS) that is capable of achieving a surface roughness equivalent to a machined finish, with arithmetic mean heights (S a ) as low as 1.0 µm. This technique utilizes the sequential application of a new, NaCl/H 2 O pulse/pulse reverse (P/PR) EP step along with a conventional DC (direct current) EP step, where P/PR expands the capability of EP by removing roughness features > 1 µm, which has been previously unattainable with DC EP alone without substantial material removal. This is achieved by independently varying pulse parameters, such as pulse width and height, allowing more control over electrodynamic processes at the part-electrolyte interface. Additionally, P/PR EP resulted in higher smoothing efficiency, where a higher degree of smoothing was achieved with less material removal when compared with conventional DC EP alone. This minimizes unwanted change in geometry from excessive metal dissolution.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Revisiting the conversion reaction voltage and the reversibility of the CuF2 electrode in Li-ion batteries

Deviation between thermodynamic and experimental voltages is one of the key issues in Li-ion conversion-type electrode materials; the factor that affects this phenomenon has not been understood well in spite of its importance. In this work, we combine first principles calculations and electrochemical experiments with characterization tools to probe the conversion reaction voltage of transition metal difluorides MF2 (M = Fe, Ni, and Cu). We find that the conversion reaction voltage is heavily dependent on the size of the metal nanoparticles generated. The surface energy of metal nanoparticles appears to penalize the reaction energy, which results in a lower voltage compared to the thermodynamic voltage of a bulk-phase reaction. Furthermore, we develop a reversible CuF2 electrode coated with NiO. Electron energy loss spectroscopy (EELS) elemental maps demonstrate that the lithiation process mostly occurs in the area of high NiO content. This suggests that NiO can be considered a suitable artificial solid electrolyte interphase that prevents direct contact between Cu nanoparticles and the electrolyte. Thus, it alleviates Cu dissolution into the electrolyte and improves the reversibility of CuF2.

Seo, Joon Kyo↗
DOE OSTI2020

Iodate interactions with calcite: implications for natural attenuation

Solid-phase interactions and speciation are important to radioiodine transport in groundwater. At the Hanford Site in Southeastern Washington State, iodate (IO 3 - ) is the main aqueous species in dilute radioiodine groundwater plumes. Like other oxyanions, IO 3 - may be incorporated into and/or adsorbed onto calcite, a common mineral at Hanford, decreasing its mobility in the environment. A series of macroscale batch experiments combined with solid phase characterization were conducted to identify variables impacting time-dependent aqueous IO 3 - removal via calcite precipitation and determine the location of IO 3 - within the calcite crystal structure. Results demonstrated 11.5-97% aqueous IO 3 - removal during initial rapid calcite precipitation. Incorporation was apparently the main removal mechanism, although later slower precipitation and/or adsorption may have also contributed to IO 3 - removal. Using a higher concentration of the calcite forming solutions (i.e., using 1M vs. 0.1M concentrations) resulted in an increase in the amount of precipitated calcite and a greater percentage of IO 3 - removed; however, calcite formed with lower molarity solutions resulted in higher IO 3 - mass (µg/g) removal. Solubility testing of laboratory produced calcites showed only small differences in solubility for calcite with and without IO 3 - incorporated into the structure. Evidence collected from SEM/FIB and TEM/SAED suggested that the IO 3 - incorporated into calcite was present in regions close to surface (implying potential easy release upon calcite dissolution).

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Phase Composition and Phase Transformation of Additively Manufactured Nickel Alloy 718 AM Bench Artifacts

Additive manufacturing (AM) technologies offer unprecedented design flexibility but are limited by a lack of understanding of the material microstructure formed under their extreme and transient processing conditions and its subsequent transformation during post-build processing. As part of the 2022 AM Bench Challenge, sponsored by the National Institute of Standards and Technology, this study focuses on the phase composition and phase evolution of AM nickel alloy 718, a nickel-based superalloy, to provide benchmark data essential for the validation of computational models for microstructural predictions. Here, we employed high-energy synchrotron X-ray diffraction, in situ synchrotron X-ray scattering, as well as high-resolution transmission electron microscopy for our analyses. The study uncovers critical aspects of the microstructure in its as-built state, its transformation during homogenization, and its phase evolution during subsequent aging heat treatment. Specifically, we identified secondary phases, monitored the dissolution and coarsening of microstructural elements, and observed the formation and stability of γ ’ and γ ” phases. The results provide the rigorous benchmark data required to understand the atomic and microstructural transformations of AM nickel alloy 718, thereby enhancing the reliability and applicability of AM models for predicting phase evolution and mechanical properties.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Beneficiation of coal using supercritical water and carbon dioxide extraction: sulfur removal

Abstract This work explores the use of carbon dioxide, water, and their mixtures as solvent for the precombustion beneficiation of raw coal without using any toxic mineral acids in the temperature range of 200–400 °C. The fluid polarity, ionic constant, and supercritical point can be adjusted by H 2 O/CO 2 ratio and temperature. Adding carbon dioxide to hydrothermal fluid also increases the ionization by forming carbonic acid. Extractions with supercritical fluids have several benefits including enhanced mass transport, ease of separation and recycle, wide range of extractive capability and tunability, better inherent safety, and in the case of carbon dioxide and water–low cost. A semi-continuous extraction system was designed and built in which pressure, temperature and the relative flow rates of CO 2 and H 2 O can be controlled. Coal powder is kept in a packed bed and the extraction is carried out at 143 bar pressure. Using sulfur as a model heteroatom, extractive efficiency is examined as a function of the temperature, fluid composition, fluid flow, and extraction time. The results indicate that carbon dioxide, water, and supercritical water-carbon dioxide (ScWC) all can effectively extract about 50% of total sulfur from bituminous coal in 1 h. Extraction above 350 °C decreased effectiveness, and extraction above the supercritical point of pure water caused hydrothermal carbonization. ScWC extraction may provide necessary control to prevent organic dissolution while removing sulfur.

DeCuir, Matthew J.↗
DOE OSTI2026

Electro-carburization of mild steel through two-step reaction in molten-salt electrolyte

The rapid carburization of mild steel is demonstrated via the electrochemical deposition of solid carbon, followed by thermochemical iron-carbon (Fe-C) reaction using a molten lithium-potassium carbonate (LiKCO 3 ) salt electrolyte and carbon dioxide as the carbon source. Depth-dependent microstructural and compositional changes in the steel are shown to be controlled by the applied cell voltage and reaction temperatures. Reaction temperatures above the Fe-C eutectoid temperature promote faster carburization due to carbon dissolution into austenite. The carbon deposition rate is regulated by the applied cell voltage: At - 2.4 V, carbon deposition occurs much faster than its diffusion into the steel, resulting in the accumulation of a carbon-rich layer exceeding 1 mm, which does not diffuse into the steel. In contrast, at - 1.8 V, all deposited carbon effectively diffuses into the steel, leaving a minimal external deposit. In both cases, carbon ingress forms a carbide-rich surface layer and precipitates additional carbides along the grain boundaries within the steel electrode. This method offers a potential approach to increase the carbon content of mild or low-carbon steel feedstocks, such as scrap or direct reduced iron, for industrial applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2017

Integrated modeling of second phase precipitation in cold-worked 316 stainless steels under irradiation

The current work combines the Cluster Dynamics (CD) technique and CALPHAD-based precipitation modeling to address the second phase precipitation in cold-worked (CW) 316 stainless steels (SS) under irradiation at 300–400 °C. CD provides the radiation enhanced diffusion and dislocation evolution as inputs for the precipitation model. The CALPHAD-based precipitation model treats the nucleation, growth and coarsening of precipitation processes based on classical nucleation theory and evolution equations, and simulates the composition, size and size distribution of precipitate phases. We benchmark the model against available experimental data at fast reactor conditions (9.4 × 10 –7 dpa/s and 390 °C) and then use the model to predict the phase instability of CW 316 SS under light water reactor (LWR) extended life conditions (7 × 10 –8 dpa/s and 275 °C). The model accurately predicts the γ' (Ni 3 Si) precipitation evolution under fast reactor conditions and that the formation of this phase is dominated by radiation enhanced segregation. The model also predicts a carbide volume fraction that agrees well with available experimental data from a PWR reactor but is much higher than the volume fraction observed in fast reactors. We propose that radiation enhanced dissolution and/or carbon depletion at sinks that occurs at high flux could be the main sources of this inconsistency. The integrated model predicts ~1.2% volume fraction for carbide and ~3.0% volume fraction for γ' for typical CW 316 SS (with 0.054 wt% carbon) under LWR extended life conditions. Finally, this work provides valuable insights into the magnitudes and mechanisms of precipitation in irradiated CW 316 SS for nuclear applications.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Lattice parameter misfit evolution during creep of a cobalt-based superalloy single crystal with cuboidal and rafted gamma-prime microstructures

A [h00] oriented Co-based superalloy single crystal was crept under tension at 940 °C=100 MPa, resulting in a P-type raft morphology with extensive particle coalescence along the [h00] loading direction. However, particle coalescence was also observed in two perpendicular directions on the (h00) plane, normal to the loading axis. Tensile creep experiments were performed with in-situ neutron diffraction at 800 °C=500 MPa on this initially rafted $\gamma$ microstructure, and for comparison at (i) 900 °C=260 MPa, and at (ii) 750 °C=875 MPa, both with initially cuboidal $\gamma$ microstructures. The alloy was shown to exhibit a positive lattice parameter misfit, and during the first hour of creep at 900 °C=260 MPa, the lattice parameter evolution indicated changes in phase composition associated with $\gamma$ dissolution as the alloy achieved phase equilibrium at 900 °C. For all three in-situ creep measurements, there was a significant divergence of the $\gamma$ and g lattice parameters as creep proceeded. The lattice parameter misfit values between the precipitates and the matrix approached their unconstrained values during creep, and were notably large compared to those of Ni-based superalloys. This is indicative of a loss of coherency at the precipitate/matrix interfaces. Such a loss of coherency at the precipitate/matrix interfaces will likely degrade certain mechanical properties such as fatigue resistance, as has been shown for the Ni-based superalloys.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Self-assembled porous metal-intermetallic nanocomposites via liquid metal dealloying

A major challenge in the synthesis of high surface area metals via subtractive processes such as dealloying is maintaining the mechanical integrity of the resulting porous materials. This issue is especially apparent in liquid metal dealloying, in which high-temperature selective dissolution in a molten metal bath leads to bicontinuous porosity formation. In liquid metal dealloying of polycrystalline alloys, grain boundary separation leads to the detachment of individual grains. In this work, we show that addition of small amounts of silicon to Nbsingle bondTi or Tasingle bondTi parent alloys leads to the generation of self-assembled arrays of intermetallic (niobium silicide or tantalum silicide) plates that are structurally merged with the usual bicontinuous porosity seen in dealloying. These silicide plates pass through grain boundaries and hold the niobium or tantalum network intact without strongly affecting the microstructural evolution during dealloying. Our approach yields a mechanically robust porous metal-intermetallic composite, which can be further processed to form tertiary materials via re-impregnation by a new third phase. The materials design strategy introduced here can be generalized to serve as a platform to form dense multiphase nanocomposites.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Structural damage and phase stability of Al 0.3 CoCrFeNi high entropy alloy under high temperature ion irradiation

In this study, an initially single phase high entropy alloy (HEA) Al 0.3 CoCrFeNi was irradiated by 3 MeV Au ions to a fluence of 6 × 10 15 cm –2 (~31 dpa at damage peak) at four different temperatures ranging from 250 °C to 650 °C. Transmission electron microscopy (TEM) and Atom probe tomography (APT) were employed to study the evolution of structural damage and phase stability with irradiation temperature. Al 0.3 CoCrFeNi exhibited a similar evolution of irradiation-induced defects with temperature as compared with conventional FCC alloys. At 250 °C and 350 °C, most of the visible irradiation-induced defects were faulted 1/3$\langle{111}\rangle$ dislocation loops. As the irradiation temperature increased to 500 °C, perfect 1/2$\langle{110}\rangle$ dislocation loops were observed along with the faulted loops. At the highest irradiation temperature 650 °C, only dislocation lines and networks could be observed. Regarding phase stability, the 3 MeV Au irradiation was observed to suppress the precipitation of (Ni, Al)-enriched nano clusters and the L12 ordered structure at irradiation temperatures 250 °C to 500 °C whereas precipitation of the B2 ordered structure was accelerated at 650 °C. This resulted in qualitatively opposite precipitation behavior between the ion irradiated damage region and unirradiated region at 500 °C and 650 °C. The opposite phase stability of the ion-irradiated damage region and unirradiated region at different temperatures is attributed to the competing effects of ballistic dissolution vs irradiation enhanced diffusion on precipitation.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Aqueous passivation of multi-principal element alloy Ni 38 Fe 20 Cr 22 Mn 10 Co 10 : Unexpected high Cr enrichment within the passive film

The aqueous passivation of a non-equiatomic Ni 38 Fe 20 Cr 22 Mn 10 Co 10 - at.% (Ni 40 Fe 20 Cr 20 Mn 10 Co 10 - wt.%) multi-principal element alloy (MPEA) was investigated in 0.1 M NaCl at pH 4 and compared to a conventional binary Ni 76 Cr 24 – at.% (Ni 78 Cr 22 – wt.%) alloy. The electrochemical behavior and oxide film characteristics were explored utilizing in-situ electrochemical and ex-situ surface-sensitive techniques. The passive film composition, thickness, and elemental valence states, as well as, the fate of each element were studied by in-situ atomic emission spectro-electrochemistry, ex-situ X-ray photoelectron spectroscopy, and atom probe tomography. The Ni 38 Fe 20 Cr 22 Mn 10 Co 10 MPEA demonstrated slightly better corrosion resistance compared to the binary Ni 76 Cr 24 , alloy. Passive films on the MPEA contained primarily Cr, and small amounts of Ni, Fe, Co and Mn, while dissolution of Ni, Fe, Co was observed. Ni 0 was enriched at the oxide/metal interface while Cr was depleted. Enrichment of Cr in the passive film occurred to a greater extent in the MPEA than for the Ni-Cr binary alloy. As a result, enrichment factors were determined and the origins of enrichment are discussed.

36 MATERIALS SCIENCE↗