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At least 1,567 records · Page 87

Diffusion Couple Investigation of the Mg-Zn System

Phase layer growth and interdiffusion in the binary Mg-Zn system was investigated utilizing solid-to-solid diffusion couples annealed at 295 , 315 and 325 C for 21, 7 and 5 days, respectively. The diffusion microstructure was examined by scanning electron microscopy and concentration profiles were determined using X-ray energy dispersive spectroscopy and electron microprobe analysis. The Mg solid solution, Mg2Zn11, MgZn2 and Mg2Zn3 in all three couples were observed in addition to the high temperature, Mg51Zn20 phase at 325 C. The MgZn2 phase was observed to grow the thickest layer, followed by the Mg2Zn3 and the Mg2Zn11 phases. Activation energies for the parabolic growth were calculated to be 105 kJ/mol and 207 kJ/mol for the Mg2Zn3 and MgZn2, respectively. Relevant interdiffusion coefficients were calculated for the phases present by analyses of concentration profiles. This study was sponsored by the US Department of Energy, Office of Energy Efficiency and Renewable Energy, Vehicle Technologies Program (DE-AC05-00OR22725).

diffusion↗

Solidification and Re-melting Phenomena During Slurry Preparation Using the RheoMetal™ Process

The melting sequence of the enthalpy exchange material (EEM) and formation of a slurry in the RheoMetal™ process was investigated. The EEM was extracted and quenched, together with a portion of the slurry at different processing times before complete melting. The EEM initially increased in size/diameter due to melt freezing onto its surface, forming a freeze-on layer. The initial growth of this layer was followed by a period of a constant diameter of the EEM with subsequent melting and decrease of diameter. Microstructural characterization of the size and morphology of different phases in the EEM and in the freeze-on layer was made. Dendritic equiaxed grains and eutectic regions containing Si particles and Cu-bearing particles and Fe-rich particles were observed in the as-cast EEM. The freeze-on layer consisted of dendritic aluminum tilted by about 30 deg in the upstream direction, caused by the rotation of the EEM. Energy dispersion spectroscopy analysis showed that the freeze-on layer had a composition corresponding to an alloy with higher melting point than the EEM and thus shielding the EEM from the surrounding melt. Microstructural changes in the EEM showed that temperature rapidly increased to 768 K (495 °C), indicated by incipient melting of the lowest temperature melting eutectic in triple junction grain boundary regions with Al{sub 2}Cu and Al{sub 5}Mg{sub 8}Si{sub 6}Cu{sub 2} phases present. As the EEM temperature increased further the binary Al-Si eutectic started to melt to form a region of a fully developed coherent mushy state. Experimental results and a thermal model indicated that as the dendrites spheroidized near to the interface at the EEM/freeze-on layer reached a mushy state with 25 pct solid fraction, coherency was lost and disintegration of the freeze-on layer took place. Subsequently, in the absence of the shielding effect from the freeze-on Layer, the EEM continued to disintegrate with a coherency limit of a solid fraction estimated to be 50 pct.

36 MATERIALS SCIENCE↗

Effects of prior deformation and annealing process on microstructure and annealing twin density in a nickel based alloy

The nickel based alloys with different Σ3 boundary density were achieved by cold-rolling and subsequent annealing treatment. Electron backscattered diffraction analysis showed that the grain size distribution changed with the processing parameters, and the discontinuous Σ3 boundary became continuous with the increase of prior deformation level. Furthermore, the Σ3 boundary density was found to be manipulated by both grain size distribution and Σ3 boundary density per grain which showed an increasing trend with prior deformation level and annealing temperature. - Highlights: • The prior deformation amount influenced the morphology of Σ3 boundary. • The grain size was not the only factor influencing Σ3 boundary density. • The fact that grain size distribution had an important effect on Σ3 boundary density was confirmed. • The nature of grain size distribution on Σ3 boundary density was revealed. • There was a great deviation in Σ3 boundary density between experimental results and predictions.

36 MATERIALS SCIENCE↗

Microstructure and transformation behavior of Ni{sub 24.7}Ti{sub 50.3}Pd{sub 25} high temperature shape-memory alloy with Sc micro-addition

NiTiPd shape-memory alloys (SMAs) are potential functional materials for use as solid-state actuators in the temperature range 100–250 °C. The present study investigates the effect of 1.0 at.% Sc micro-addition to Ni{sub 24.7}Ti{sub 50.3}Pd{sub 25} alloy, Sc replacing either Ti or Ni. Results show that all the three alloys studied have stable transformation behavior on stress-free thermal cycling and hence, are suitable for cyclic actuation applications. However, the addition of Sc to NiTiPd alloy leads to decrease of transformation temperatures, the magnitude of decrease being greater for the alloy with Sc replacing Ni. The martensite finish (M{sub f}) temperature of 181 °C for the NiTiPd alloy decreased to 139 °C for Sc replacing Ti and 83 °C for Sc replacing Ni. Also, the indentation modulus of NiTiPdSc (Sc replacing Ni) alloy is found to be significantly low compared to the other alloys. Analysis indicates that the observed differences in the alloy properties are related to the solubility of Sc in the NiTiPd matrix. While the quaternary NiTiPdSc alloy, Sc replacing Ti, has a single phase microstructure, the alloy with Sc replacing Ni shows the presence of Sc-rich and TiPd-type second phases in the microstructure. TEM examination revealed that the TiPd-type phase has a distinct rod-like morphology (30–50 nm) arranged in a grid-like structure. The transformation and indentation behavior of the alloys is elucidated using thermodynamic calculations of frictional energy and an electronic structure based analysis. - Highlights: • TEM of Ni{sub 23.7}Ti{sub 50.3}Pd{sub 25}Sc{sub 1} showed distinct grid of TiPd-type phase nanorods < 50 nm. • Stress-free thermal cycling of all the three alloys showed stable transformation behavior. • Ni{sub 24.7}Ti{sub 49.3}Pd{sub 25}Sc{sub 1} and Ni{sub 23.7}Ti{sub 50.3}Pd{sub 25}Sc{sub 1} showed single and multiphase structures. • Sc micro-addition (1 at.%) to Ni{sub 24.7}Ti{sub 50.3}Pd{sub 25} alloy decreased TTs significantly. • Ni{sub 23.7}Ti{sub 50.3}Pd{sub 25}Sc{sub 1} exhibited lower modulus of 67 GPa to 85 GPa of Ni{sub 24.7}Ti{sub 50.3}Pd{sub 25}.

36 MATERIALS SCIENCE↗

Establishing model credibility for process-microstructure-property relationships in additive manufacturing using exascale computing

Additive Manufacturing (AM) of alloys holds significant promise as a disruptive technology in various industries, yet its adoption is often hindered by challenges in achieving consistent part quality. These issues are primarily due to the complex process-microstructure-property (PSP) relationships inherent to AM. Computational models can greatly aid in understanding these relationships, but their widespread impact and adoption has been limited by a lack of validated, open-source, and computationally efficient PSP modeling frameworks and hardware limitations. Here, this study leverages the ExaAM software suite and data from the AMBench-2018 series of laser powder bed fusion (LPBF) benchmark experiments to perform a comprehensive model assessment, including verification, validation, sensitivity analysis, and uncertainty quantification. The RADICAL-EnTK workflow manager was used to perform an ensemble of heat transport, solidification, and mechanical response simulations on the exascale computer Frontier, considering uncertainties in critical model inputs such as laser spot size and nucleation parameters, and consisting of 125 explicit grain structure simulations and 7875 crystal plasticity simulations. For a selected location within the Inconel 625 AMBench-2018 test artifact, sensitivity analysis and uncertainty quantification were performed using the predicted distributions of grain structure and mechanical properties. Qualitative agreement was found between the predicted grain size and texture and the observed AMBench-2018 microstructure, the mean predicted yield stress was within 5% of the experimental measurement mean, and the mean predicted engineering stress at 5% strain was within 10% of the experimental measurement mean. The insights gained from development and validation of the ExaAM PSP modeling framework will help guide future directions for enhancing the credibility and reliability of PSP models in AM, thereby accelerating the adoption of AM technologies in various industries.

Additive manufacturing↗

Dielectric, Electrical and Magnetic Properties of PbZr{sub 0.53}Ti{sub 0.47} O{sub 3}-Ni{sub 0.65}Zn{sub 0.35}Fe{sub 2}O{sub 4} Multiferroic Composite

Novel ferroelectric/ferrimagnetic multiferroic composite of PbZr{sub 0.53}Ti{sub 0.47}O{sub 3}(PZT)-Ni{sub 0.65}Zn{sub 0.35}Fe{sub 2}O{sub 4}(NZFO)(80:20 wt%) were fabricated by a conventional solid-state reaction technique. Structural analysis carried out by X ray diffraction technique, reveals the presence of both PZT and NZFO binary phase in this composite. Detailed analysis of dielectric and ferroelectric properties in a wide temperature range (30-400 deg. C) showed a ferro to paraelectric phase transition at 293 deg. C. The electrical properties of the composite samples were investigated in a frequency range of 100 Hz-1 MHz using complex impedance spectroscopic technique. Complex impedance analysis showed the presence of grains and grain boundaries contribution for electrical conduction in this composite. Temperature dependent magnetic hysteresis (M-H) loops in the temperature range of 80-300 K show excellent non-saturating ferrimagnetic behavior with coercive field (Hc) in the range of 60-45 Oe in this multiferroic PZT/NZFO composite.

36 MATERIALS SCIENCE↗

Stability of Catalyzed Magnesium Hydride Nanocrystalline During Hydrogen Cycling. Part II: Microstructure Evolution

In Part I, the cyclic stabilities of the kinetics of catalyzed MgH2 systems including MgH2–TiH2, MgH2–TiMn2, and MgH2–VTiCr were investigated, showing stable kinetics at 300 °C but deteriorations of the hydrogenation kinetics at temperatures below 150 °C. The present Part II describes the characterization of uncycled and cycled catalyzed MgH2 by X-ray diffraction (XRD), scanning electron microscopy (SEM), transmission electron microscopy (TEM), and X-ray photoelectron spectroscopy (XPS) analysis. XRD analysis shows the crystallite sizes of the Mg and MgH2 significantly increased after the cycling. The mean crystallite sizes of the catalysts (TiH2 and VTiCr) increased moderately after the cycling. SEM and TEM imaging were used to compare the microstructures of uncycled (as-milled) and cycled materials, revealing a drastic change of the microstructure after 100 cycles. In particular, results from energy-dispersive spectroscopy (EDS) mapping show that a change of distribution of the catalyst particles in the Mg and MgH2 phase occurred during the cycling.

Zhou, Chengshang↗

Application of Al-2La-1B Grain Refiner to Al-10Si-0.3Mg Casting Alloy

This paper reports the application and microstructure refining effect of an Al-2La-1B grain refiner in Al-10Si-0.3Mg casting alloy. Compared with the traditional Al-5Ti-1B refiner, Al-2La-1B refiner shows better performances on the grain refinement of Al-10Si-0.3Mg alloy. Transmission electron microscopy analysis suggests that the crystallite structure features of LaB6 are beneficial to the heterogeneous nucleation of α-Al grains. Regarding the mechanical performances, tensile properties of Al-10Si-0.3Mg casting alloy are prominently improved, due to the refined microstructures.

36 MATERIALS SCIENCE↗

Uncertainty Quantification for Dissimilar Material Joints Under Corrosion Environment

Abstract Self-Piercing Riveting (SPR) is one of the most commonly used methods for joining dissimilar materials in the automotive industry. These joints are popular due to their adaptability, high performance and short cycle time. However, since these joints involve two dissimilar materials, they are susceptible to galvanic corrosion in the presence of an electrolyte which is driven by the difference in the equilibrium potential of the metals. This can affect the safety and resilience of these joints. In this paper, we focus on galvanic corrosion in Al-Fe SPR joints. A Machine learning (ML) based surrogate model, which is based off of FE simulations, for statistical corrosion analysis is developed. This model enables the resilience and reliability analysis of SPR joints under corrosion environment. In this study, first a physics-based finite element (FE) corrosion model has been developed to simulate the galvanic corrosion between a Fe cathode and an Al anode of a SPR joint. This model takes into account the effect of the crystal microstructure of the Al anode and the precipitation of the corrosion product. Several geometric and environmental factors including crevice gap, roughness of anode, conductivity, pH and the temperature of the electrolyte that effect corrosion are investigated. A thorough Uncertainty Quantification (UQ) analysis is conducted for the overall corrosion behavior of the Fe-Al SPR joints using a novelistic Probabilistic Confidence-Based Adaptive Sampling (PCAS) technique. PCAS is used to train the surrogate model by identifying the critical sampling points and thus reducing the overall computational costs. It is found that the electrolyte temperature has the largest effects on the material loss and needs to be managed closely for better corrosion control. By understanding the corrosion performance and resultant uncertainty impact on SPR joints, the reliability and resilience of these joints can be improved.

36 MATERIALS SCIENCE↗

Corrosion Behavior of Laser-Brazed Surface Made by Joining of AA6082 and Galvanized Steel

In the present study, a galvanized steel and a AA6082 aluminum alloy sheet of 2 mm thick were weld-brazed by applying laser and using 2-mm-diameter solid Al-12% Si filler wire at 2.5 m/min wire feed rate and 2 m/min laser scan speed at varying laser power (4.0, 3.5, 3.0 kW) in flange configuration. The microstructural investigation of the laser weld-brazed joints revealed the presence of two-layered intermetallic compound at steel/braze seam interface. The corresponding x-ray diffraction analysis of the steel/braze seam interface showed the presence of Al-Fe-Si-based ternary intermetallic phases. SEM and EDS analysis of the braze seam revealed the presence of α-Al grains surrounded by Mg{sub 2}Si phase in the grain boundary region. Fine intermetallic layer was observed at lower heat-input condition. The corrosion performance of the brazed joints was studied with the help of immersion, salt spray, and electrochemical polarization tests in different electrolytes containing NaCl salt. Brazed joints experienced galvanic corrosion during immersed in corrosive media. From the salt spray test, it was revealed that galvanized steel was highly susceptible to corrosion compared to Al-rich phase. The polarization results showed a substantial change in corrosion resistance from steel interface to the brazed region due to the variation in microstructure. The samples brazed with low heat-input showed better corrosion resistance as compared to the joints made with high heat-input. Post-corrosion microstructure revealed intergranular corrosion at the brazed joint along with pit formation.

36 MATERIALS SCIENCE↗

Synthesis and behavior of bulk iron nitride soft magnets via high-pressure spark plasma sintering

Abstract In this study, dense bulk iron nitrides (Fe x N) were synthesized for the first time ever using spark plasma sintering (SPS) of Fe x N powders. The Fe 4 N phase of iron nitride in particular has significant potential to serve as a new soft magnetic material in both transformer and inductor cores and electrical machines. The density of SPSed Fe x N increased with SPS temperature and pressure. The microstructure of the consolidated bulk Fe x N was characterized with X-ray diffraction (XRD), scanning electron microscopy (SEM), transmission electron microscopy (TEM), and superconducting quantum interference device (SQUID) magnetometry. XRD revealed a primary phase of Fe 4 N with secondary phases of Fe 3 N and metallic iron. Finite element analysis (FEA) was also applied to investigate and explain localized heating and temperature distribution during SPS. The effects of processing on interface bonding formation and phase evolution were investigated and discussed in detail to provide insight into fundamental phenomena and microstructural evolution in SPSed Fe x N. Graphic abstract

36 MATERIALS SCIENCE↗

Microstructure heterogeneity after the ECAP process and its influence on recrystallization in aluminium

The main purpose of the present work is to describe the qualitative and quantitative behaviours of aluminium during high strain plastic deformation and the effect of deformation on the subsequent recrystallization process. An Electron Backscatter Diffraction analysis of aluminium after the Equal channel angular pressing (ECAP) and recrystallization process is presented. In order to do this, several topological maps are measured for samples processed by 4 and 8 passes and recrystallized. The processing was conducted with route C. For all samples, distributions of grain size, misorientation, image quality factor (IQ) and texture were preceded and then analysed in some detail. - Highlights: ► Describe the microstructure fragmentation in aluminum. ► High strain plastic deformation and effect of deformation on recrystallization. ► The microstructure fragmentation and its influence on recrystallization. ► Image quality factor and misorientation characteristics are examined using EBSD.

36 MATERIALS SCIENCE↗

Sintering and characterization of SrBi{sub 2}Ta{sub 2}O{sub 9} obtained by high-pressure processing at low temperatures

High-pressure processing is a very attractive approach for the production of materials with new and/or improved properties. In this work, pressures in the order of 7.7 GPa and 2.5 GPa were induced in SrBi{sub 2}Ta{sub 2}O{sub 9} samples at different temperatures placed in a specific reaction cell and generated different effects on phase formation. The microstructural evolution during high-pressure processing was investigated by scanning electron microscopy in association with energy dispersion spectroscopy and with the support of an X-ray diffraction analyzer. Frequency response analysis was used to obtain the dielectric curves by electrochemical impedance spectroscopy. A SrBi{sub 2}Ta{sub 2}O{sub 9} single-phase sample, treated at 2.5 GPa and 900 °C, was used to evaluate the electrical properties, obtaining a dielectric response similar to SrBi{sub 2}Ta{sub 2}O{sub 9} samples sintered by conventional processes at temperatures above 1000 °C. In addition, by this method, it was possible to obtain ceramics with uniform microstructure and a relative density of 93%. - Highlights: • The first production of SrBi{sub 2}Ta{sub 2}O{sub 9} using the technique of high-pressure processing. • The ability to produce single-phase SrBi{sub 2}Ta{sub 2}O{sub 9} treated at 2.5 GPa and 900 °C. • The electrical properties are compatible with SBT sintered at high temperatures.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Characterization of Crystallographic Structures Using Bragg-Edge Neutron Imaging at the Spallation Neutron Source

Over the past decade, wavelength-dependent neutron radiography, also known as Bragg-edge imaging, has been employed as a non-destructive bulk characterization method due to its sensitivity to coherent elastic neutron scattering that is associated with crystalline structures. Several analysis approaches have been developed to quantitatively determine crystalline orientation, lattice strain, and phase distribution. In this study, we report a systematic investigation of the crystal structures of metallic materials (such as selected textureless powder samples and additively manufactured (AM) Inconel 718 samples), using Bragg-edge imaging at the Oak Ridge National Laboratory (ORNL) Spallation Neutron Source (SNS). Firstly, we have implemented a phenomenological Gaussian-based fitting in a Python-based computer called iBeatles. Secondly, we have developed a model-based approach to analyze Bragg-edge transmission spectra, which allows quantitative determination of the crystallographic attributes. Moreover, neutron diffraction measurements were carried out to validate the Bragg-edge analytical methods. These results demonstrate that the microstructural complexity (in this case, texture) plays a key role in determining the crystallographic parameters (lattice constant or interplanar spacing), which implies that the Bragg-edge image analysis methods must be carefully selected based on the material structures.

47 OTHER INSTRUMENTATION↗

Effect of polycyclosilane microstructure on thermal properties

Thermal characterization of polysilanes has focused on the influence of organic side chains, whereas little is understood about the influence of silane backbone microstructure on thermal stability, phase properties, and pyrolysis. To address this knowledge gap, we prepared three distinct polycyclosilanes: linear polymers synthesized from the cyclosilane building blocks 1,4Si 6 and 1,3Si 6 , as well as a cyclic polymer of 1,3Si 6 . Thermal properties across the temperature range 25 to 600 °C were investigated using differential scanning calromietry (DSC) and thermogravimetric analysis (TGA). We found differences between linear and cyclic materials, including a phase transition unique to the cyclic polymer and lower rates of mass loss during pyrolysis. Density functional theory (DFT) calculations provided insight into microstructure-dependent pyrolysis.

36 MATERIALS SCIENCE↗

Electrical transport properties of manganese containing pyrochlore type semiconducting oxides using impedance analyses

Graphical abstract: DC conductivity variation of CaCe{sub 1−x}Mn{sub x}SnNbO{sub 7−δ} (x = 0, 0.2, 0.4 and 0.6) with inverse of temperature. Variation of conductivity with Mn concentration at 600 °C is shown in the inset. Display Omitted Highlights: ► We have observed that the structural ordering as well as grain size increase with Mn substitution. ► Impedance analysis proved that a correlated barrier hopping type conduction mechanism is involved in the materials. ► Activation energy as well as electrical conductivity increases with increase in Mn substitution. ► Localization of electrons associated with Mn{sup 2+} and structural ordering are the key factors for the increased activation energy with Mn substitution. ► All the materials showed good NTC thermistor properties. -- Abstract: A new series of manganese containing pyrochlore type semiconducting oxides CaCe{sub 1−x}Mn{sub x}SnNbO{sub 7−δ} (x = 0, 0.2, 0.4 and 0.6) have been synthesized to study the effect of Mn substitution on the structure, microstructure and electrical properties of these samples. X-ray diffraction and scanning electron microscopy studies revealed an increase of structural ordering and grain size respectively with increase of Mn substitution. Rietveld analysis and Raman spectroscopy were also employed to corroborate the XRD results. The bulk resistance measurements with temperature exhibit negative temperature coefficient behavior. The impedance analysis of the samples revealed a non-Debye type relaxation existed in the materials. The ac conductivity variation with temperature and frequency indicates a correlated barrier hopping type conduction mechanism in these materials. The barrier height and the intersite separation for hopping influence the electrical conductivity of these samples and are found to be a function of localization of electrons associated with the Mn{sup 2+} ions and the unit cell volume respectively. The Mn substitution increases both electrical conductivity and activation energy contrastingly. This unusual behavior has been explained by correlating the structure, microstructure, defect states, electron localization and intersite separation with the conductivity data of the samples.

36 MATERIALS SCIENCE↗

Utilization of the Critic Subnetwork of a Generative Adversarial Network as Detector of Morphological Material Change in Image Data

The resolution of computed tomography (CT) has become high enough to monitor morphological changes due to aging in materials in long-term applications. For this work, we explored the utility of the critic of a generative adversarial network (GAN) to automatically detect such changes. The GAN was trained with images of pristine Pharmatose, which is used as a surrogate energetic material. It is important to note that images of the material with altered morphology were only used during the test phase. The GAN-generated images reproduced the microstructure of Pharmatose well, although some unrealistic particle fusion was seen. Calculated morphological metrics (volume fraction, interfacial line length, and local thickness) for the synthetic images also showed good agreement with the training data, albeit with signs of mode collapse in the interfacial line length. While the critic exposed changes in particle size, it showed limited ability to distinguish images by particle shape. The detection of shape differences was also a more challenging task for the selected morphological metrics that related to energetic material performance. We further tested the critic with images of aged Pharmatose. Subtle changes due to aging are difficult for the human analyst to detect; but both critic and morphological metrics analysis showed image differentiation.

36 MATERIALS SCIENCE↗

Microstructural and mechanical characteristics of Ni–Cr thin films

Highlights: • Ni–Cr thin films of varied composition deposited by DC magnetron co-sputtering. • Thin film with Ni–Cr: 80–20 at% composition exhibits most distinct behavior. • The films were tensile tested and exhibited no cracking till the substrate yielding. - Abstract: Ni–Cr alloy thin films have been deposited using magnetron co-sputtering technique at room temperature. Crystal structure was evaluated using GIXRD. Ni–Cr solid solution upto 40 at% of Cr exhibited fcc solid solution of Cr in Ni and beyond that it exhibited bcc solid solution of Ni in Cr. X-ray diffraction analysis shows formation of (1 1 1) fiber texture in fcc and (2 2 0) fiber texture in bcc Ni–Cr thin films. Electron microscopy in both in-plane and transverse direction of the film surface revealed the presence of columnar microstructure for films having Cr upto 40 at%. Mechanical properties of the films are evaluated using nanoindentation. The modulus values increased with increase of Cr at% till the film is fcc. With further increase in Cr at% the modulus values decreased. Ni–Cr film with 20 at% Ni exhibits reduction in modulus and is correlated to the poor crystallization of the film as reflected in XRD analysis. The Ni–Cr thin film with 80 at% Ni and 20 at% Cr exhibited the most distinct columnar structure with highest electrical resistivity, indentation hardness and elastic modulus.

36 MATERIALS SCIENCE↗