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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 1,729 records · Page 96
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Stress-induced α″ phase in a beta Ti–19Nb–1.5Mo–4Zr–8Sn alloy

Highlights: • Morphologies/distributions of α″ produced by stretching/rolling are similar. • Under small deformation, α″ martensite consists of parallel lamellar structures. • Under larger deformations, martensite has ladder-like pattern and parallel ellipsoids. • With the increase of deformation hardness decreases firstly and then increases. - Abstract: The morphological evolution of the stress-induced α″ martensite with increases in the stretching and rolling deformation degrees as well as the related orientation relationship were investigated in a β titanium alloy (Ti–19Nb–1.5Mo–4Zr–8Sn)·For a stretching deformation of 1%, the α″ martensite exhibited a packet morphology consisting of parallel lamellar structures. On the other hand, in the 2%-rolled sample, the α″ martensite exhibited a long lath-like distribution, which was accompanied by a few small pieces. With an increase in the deformation degree, the α″ martensite gradually exhibited a ladder-like structure consisting of long and short α″ laths or ellipsoids. The existence of these self-accommodating martensitic variants decreased the elastic energy. The parallel α″ laths present within a single packet were found to have the same orientation. The interface between the α″ and β phases was coherent, and their lattice constant relationships were identified as √2a{sub β}≈b{sub α″}≈c{sub α″} and a{sub β} ≈ a{sub α″}. Further, with the increase in the deformation degree, the hardness of the alloy first decreased and then increased; this was the case both the stretched as well as the rolled samples.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Origin of texture development in orthorhombic uranium

We study texture evolution of alpha-uranium (α-U) during plane strain compression and uniaxial compression to high strains at different temperatures. We combine a multiscale polycrystal constitutive model and detailed analysis of texture data to uncover the slip and twinning modes responsible for the formation of individual texture components. The analysis indicates that during plane strain compression, floor slip (001)[100] results in the formation of two pronounced {001}{001} texture peaks tilted 10–15° away from the normal toward the rolling direction. During both high-temperature (573 K) through-thickness compression and plane strain compression, the active slip modes are floor slip (001)[100] and chimney slip 1/2{110} <11¯0> with slightly different ratios. {130} <31¯0> deformation twinning is profuse during rolling and in-plane compression and decreases with increasing temperature, but is not as active for through-thickness compression. Lastly, we comment on some similarities between rolling textures of α-U, which has a c/a ratio of 1.734, and those that develop in hexagonal close packed metals with similarly high c/a ratios like Zn (1.856) and Cd (1.885) and are dominated by basal slip.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Oil miscible phosphonium-phosphate ionic liquid as novel antiwear and antipitting additive for low-viscosity rear axle lubricants

Here we explored the feasibility of using a phosphonium phosphate ionic liquid as a candidate anti-wear and anti-pitting additive for rear axle lubricant. This particular IL was first added to a VHVI8 base oil at 2–3% concentration and demonstrated effective surface protection for wear and micro-cracking under rolling-sliding contacts. The promising results directed to a step further to produce a series of IL-containing low-viscosity (about a half of SAE 75W-90) fully formulated gear oils. Selected IL-containing experimental oils showed superior mitigation of rolling contact fatigue to a commercial SAE 75W-90 gear oil in bench-scale rolling-sliding tests. Full-scale hub dynamometer tests were then conducted and demonstrated more than 3% power output and torque generation for an IL-containing low-viscosity gear oil benchmarked against commercial baselines.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Processing and mechanical properties - 2016-0032

Hot extrusion is used within the forming route of cladding tubes to deform the billets into tube hollows, which are then cold-rolled to produce the final tubes with the suitable properties for in-reactor use. The hot extrusion goals are to give the appropriate geometry for cold pilgering (diameter and wall thickness suitable for cold-rolling mills, good concentricity) without surface defects and microstructural heterogeneities, which are detrimental for subsequent rolling. To ensure a good quality of the tube hollows, extrusion parameters (e.g., temperature of the billet, ram speed, extrusion ratio, lubrication) and extrusion tools have to be chosen as a function of the press capacity and mechanical and microstructural properties of the extruded alloy. For this purpose, finite-element and analytical models are used in addition to experimental tests. These models, particularly the former, can take into account the thermomechanical coupling that occurs in the tube and the tools during extrusion and provides a good prediction of the extrusion pressure and thermomechanical history of the extruded product. Together with a microstructural evolution model identified with small-scale extrusion tests, torsion tests, and heat treatments, this last result can also be used to calculate the fragmentation of the microstructure in the die and the meta-dynamic recrystallization after extrusion. Once validated against experimental data, numerical models were used to better understand and master the extrusion loads, the microstructure evolutions at the front end of the extruded tubes, and the temperature and stresses applied to the tools. (authors)

36 MATERIALS SCIENCE↗
DOE OSTI2016

Characterization of Tubing from Advanced ODS alloy (FCRD-NFA1)

Fabrication methods are being developed and tested for producing fuel clad tubing of the advanced ODS 14YWT and FCRD-NFA1 ferritic alloys. Three fabrication methods were based on plastically deforming a machined thick-wall tube sample of the ODS alloys by pilgering, hydrostatic extrusion or drawing to decrease the outer diameter and wall thickness and increase the length of the final tube. The fourth fabrication method consisted of the additive manufacturing approach involving solid-state spray deposition (SSSD) of ball milled and annealed powder of 14YWT for producing thin-wall tubes. Of the four fabrication methods, two methods were successful at producing tubing for further characterization: production of tubing by high-velocity oxy-fuel spray forming and production of tubing using high-temperature hydrostatic extrusion. The characterization described shows through neutron diffraction the texture produced during extrusion while maintaining the beneficial oxide dispersion. In this research, the parameters for innovative thermal spray deposition and hot extrusion processing methods have been developed to produce the final nanostructured ferritic alloy (NFA) tubes having approximately 0.5 mm wall thickness. Effect of different processing routes on texture and grain boundary characteristics has been investigated. It was found that hydrostatic extrusion results in combination of plane strain and shear deformations which generate rolling textures of α- and γ-fibers on {001}<110> and {111}<110> together with a shear texture of ζ-fiber on {011}<211> and {011}<011>. On the other hand, multi-step plane strain deformation in cross directions leads to a strong rolling textures of θ- and ε-fiber on {001}<110> together with weak γ-fiber on {111}<112>. Even though the amount of the equivalent strain is similar, shear deformation leads to much lower texture indexes compared to the plane strain deformations. Moreover, while 50% of hot rolling brings about a large number of high-angle grain boundaries (HAB), 44% of shear deformation results in large amount of low-angle boundaries (LAB) showing the incomplete recrystallization.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2016

Non-destructive Quantitative Phase Analysis and Microstructural Characterization of Zirconium Coated U-10Mo Fuel Foils via Neutron Diffraction

This report uses neutron diffraction to investigate the crystal phase composition of uranium-molybdenum alloy foils (U-10Mo) for the CONVERT MP-1 Reactor Conversion Project, and determines the effect on alpha-uranium contamination following the deposition of a Zr metal diffusion layer by various methods: plasma spray deposition of Zr powders at LANL and hot co-rolling with Zr foils at BWXT. In summary, there is minimal decomposition of the gamma phase U-10Mo foil to alpha phase contamination following both plasma spraying and hot co-rolling. The average unit cell volume, i.e. lattice spacing, of the Zr layer can be mathematically extracted from the diffraction data; co-rolled Zr matches well with literature values of bulk Zr, while plasma sprayed Zr shows a slight increase in the lattice spacing, indicative of interstitial oxygen in the lattice. Neutron diffraction is a beneficial alternative to conventional methods of phase composition, i.e. x ray diffraction (XRD) and destructive metallography. XRD has minimal penetration depth in high atomic number materials, particularly uranium, and can only probe the first few microns of the fuel plate; neutrons pass completely through the foil, allowing for bulk analysis of the foil composition and no issues with addition of cladding layers, as in the final, aluminum-clad reactor fuel plates. Destructive metallography requires skilled technicians, cutting of the foil into small sections, hazardous etching conditions, long polishing and microscopy times, etc.; the neutron diffraction system has an automated sample loader and can fit larger foils, so there is minimal analysis preparation; the total spectrum acquisition time is ~ 1 hour per sample. The neutron diffraction results are limited by spectra refinement/calculation times and the availability of the neutron beam source. In the case of LANSCE at Los Alamos, the beam operates ~50% of the year. Following the lessons learned from these preliminary results, optimizations to the process and analysis can be made, and neutron diffraction can become a viable and efficient technique for gamma/alpha phase composition determination for nuclear fuels.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Fully R2R-Printed Carbon-Nanotube-Based Limitless Length of Flexible Active-Matrix for Electrophoretic Display Application

A limitless-length flexible active-matrix implies that virtually any surface can be rendered into an interactive medium when laminated with electrophoretic or organic light-emitting diode sheets. However, performance, cost, and size limitations of current fabrication technologies and semiconducting materials, typically utilized in thin film transistor (TFT) active matrices (TFT-AMs), have hindered progress, thus preventing the realization of fully printed TFT-AMs on a plastic roll. Here, a new high-purity semiconducting single-walled carbon nanotube (s-SWCNT) ink is prepared by first isolating 99.9% pure s-SWCNTs via conjugated polymer extraction, and then utilizing a ligand-exchange method to formulate a novel hydrophilic gravure-compatible semiconducting ink. Based on the s-SWCNT ink, a fully additive manufacturing process using roll-to-roll (R2R) gravure printing enables the fabrication of a flexible TFT-AM, overcoming performance, cost, and size limitations. TFT-AMs with 10 to 40 PPI resolution where average mobility of 0.23 ± 0.12 cm 2 V –1 s –1 , average on–off ratio of 10 4.1 , and threshold voltage variation of ±13% are attained. As a proof of concept, an inexpensive and flexible electrophoretic display is demonstrated by simply laminating an electrophoretic sheet onto the R2R gravure-printed s-SWCNT-based TFT-AM.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Research on Phase Reaction of Nb{sub 3}Al Precursor During Rapid Heating Process

Short samples of Nb{sub 3}Al precursor are heated by Ohm heating. The curves of temperature vs heating time are investigated to study the phase reaction of jelly-roll precursor and in situ powder-in-tube precursor during the rapid heating process. A short constant temperature process occurs at about 2000 {sup ∘}C. It is proved that the reaction that generates body-centered cubic (BCC) solid solution phase is reversible. For jelly-roll precursor, metallographic images show that no reaction occurs between Nb/Al roll and Nb matrix. Voids and cracks become larger as the precursor is processed for multiple times. For in situ powder-in-tube precursor, Nb and Al powder is not reacted completely. Using smaller original Nb powder and Al powder is good for the formation of BCC solid solution.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Characterization of Directional Elastoplastic Properties of Al/Cu Bimetallic Sheet

The paper presents the results of the study aimed at determining the elastoplastic properties of an Al/Cu bimetallic sheet consisting of aluminum and copper layers, which were joined by cold rolling. The values of elasticity coefficients in three orthotropic planes as well as the Kirchhoff modulus, and coefficient of internal friction in the perpendicular direction to the lamination were determined. The subjects of the analysis were also the values of limit stresses, uniform energy of elastic and plastic strain per unit volume, and coefficients of the hardening curve and normal anisotropy. The tests were carried out on bimetallic specimens with varying thicknesses of the copper layer, cut from the Al/Cu sheet in the direction of rolling and in the direction perpendicular to it. Two methods of determining the directional values of mechanical parameters were used in the tests, i.e., the uniaxial quasi-static tensile test and the dynamic acoustic resonance method. It was concluded that these methods made it possible to determine directional elastoplastic properties of the Al/Cu bimetallic sheet taking into account the variable share of components in the bimetal and the direction of cutting out specimens from cold-rolled sheet.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Effects of chemical segregation on ductility-anisotropy in high strength Fe-Mn-Al-C lightweight austenitic steels

Ductile Fe-Mn-Al-C lightweight steels offer great potential as high specific strength materials for weight critical applications. In the present work, very high yield (~1 GPa) and ultimate tensile strength levels (~1.5 GPa) were obtained along the rolling and transverse directions of Fe-30Mn-8.5Al-0.9Si-0.9C-0.5Mo (wt.%), with high tensile elongation to failure of ~35%. This excellent mechanical behavior was attributed to the nanoscale, ordered κ-carbide precipitates formed during aging after rolling. However, tensile ductility was not isotropic through all directions of the rolled plate. In particular, the ductility was consistently lower than 5% true strain along the normal direction. Upon detailed microstructural investigations, micro-scale lamellar chemical micro-segregation bands were detected, which caused the observed anisotropic embrittlement along certain plate directions. These bands resulted in low failure strains along the normal direction since it is oriented perpendicular to these chemical segregation bands, resulting in a failure type reminiscent of delamination-induced cleavage fracture. Chemical segregation causes an inhomogeneous κ-carbide precipitate distribution upon aging, producing more pronounced mechanical anisotropy after peak-aging as compared to the solution heat treated samples. Surprisingly, deformation twinning was observed after tensile deformation of solution-heat treated specimens via electron-backscatter diffraction experiments, which is anomalous for a high stacking faulty energy (SFE) material. Further, it was proposed that chemical micro-segregation promotes locally different SFE regions, leading to deformation twinning in this nominally high SFE material. Overall, this work demonstrates the effects of chemical segregation on mechanical properties and microstructural evolution in a high performance, lightweight Fe-Mn-Al-C steel.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2018

Enhancing workability in sheet production of high silicon content electrical steel through large shear deformation

Enhanced workability, as characterized by the magnitude and heterogeneity of accommodated plastic strains during sheet processing, is demonstrated in high Si content Fe-Si alloys containing 4 and 6.5 wt% Si using two single-step, simple-shear deformation techniques – peeling and large strain extrusion machining (LSEM). The model Fe-Si material system was selected for its intrinsically poor material workability, and well-known applications potential in next-generation electric machines. In a comparative study of the deformation characteristics of the shear processes with conventional rolling, two distinct manifestations of workability are observed. For rolling, the relatively diffuse and unconfined deformation zone geometry leads to cracking at low strains, with sheet structures characterized by extensive deformation twinning and banding. Workpiece pre-heating is required to improve the workability in rolling. In contrast, peeling and LSEM produce continuous sheet at large plastic strains without cracking, the result of more confined deformation geometries that enhances the workability. Peeling, however, results in heterogeneous, shear-banded microstructures, pointing to a second type of workability issue – flow localization – that limits sheet processing. This shear banding is to a large extent facilitated by unrestricted flow at the sheet surface, unavoidable in peeling. With additional confinement of this free surface deformation and appropriately designed deformation zone geometry, LSEM is shown to suppress shear banding, resulting in continuous sheet with homogeneous microstructure. Thus LSEM is shown to produce the greatest enhancement in process workability for producing sheet. In conclusion, these workability findings are explained and discussed based on differences in process mechanics and deformation zone geometry.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Effects of Zn and Ca on the deformation texture evolution of Mg–Zn–Ca alloys at elevated temperatures

This work utilized crystal plasticity simulations and experimental thermo-mechanical processing to examine how Zn and Ca content affects texture evolution in Mg–Zn–Ca alloys during simulated hot rolling. Four different compositions were studied: unalloyed Mg and three Mg alloys of ZX0p50 (Mg- 0.5 wt% Zn- 0.1 wt% Ca), ZX30 (Mg-3 wt% Zn- 0.1 wt% Ca), and ZX31 (Mg-3 wt% Zn- 0.3 wt% Ca). Multi-pass Gleeble experiments simulated hot rolling using plane strain conditions. Unalloyed Mg developed a strong basal texture, while the addition of Zn and Ca significantly weakened the texture in ZX30 and ZX31; this reduction was not seen in ZX0p50. Notably, ZX31 exhibited a split basal texture aligned with the rolling direction. Crystal plasticity simulations revealed that the weaker basal texture in ZX30 and ZX31 resulted from reduced activation of basal and twinning modes compared to unalloyed Mg and Zx0p50. Increased Zn and Ca content raised the ratios of basal to pyramidal critical resolved sheer stress (CRSS) and twin to pyramidal CRSS, enhancing pyramidal slip activity and weakening the basal texture. Extension twinning played a critical role in texture development during the first deformation pass. In unalloyed Mg and ZX0p50, twinning led to a strong basal texture, while ZX30 and ZX31 had weak basal textures that increased only slightly with further deformation. The split basal poles simulated in ZX31 were consistent with the experimental findings, highlighting the interplay between alloy composition and texture evolution.

Crystal plasticity finite element↗
DOE OSTI2019

Simulations of post-recrystallization grain growth in monolithic U–10Mo fuel processing

In this study, the Potts Model was used to simulate the post-recrystallization grain growth behavior of U-10 wt.% Mo (U-10Mo). The fabrication process for monolithic U-10Mo fuels involves multiple stages of rolling, during which spatially heterogeneous distributions of second phase particles form in the alloy microstructure. These particles can strongly affect the post-recrystallization grain growth process. Absent particle dissolution effects, U-10Mo grain growth has been observed stagnating at increasing grain size with increasing annealing temperature. In this work, we simulate this effect in the Potts Model by making adjustments to the non-physical Monte Carlo temperature. This modification was used to account for the weakening pinning effect of the second phases with elevated annealing temperature. Simulated average grain sizes and grain size distributions were compared with experimentally obtained results for 700 °C, 800 °C, and 900 °C anneals of duration up to 240 hours. These simulations achieved reasonable agreement with experimentally observed grain growth behavior, but showed narrower grain size distributions. It is believed that this disagreement originates from the formation of bands of second-phase particles during rolling. Finally, these results demonstrate the capability to evaluate the post-recrystallization grain growth behavior for U-10Mo as a function of previous homogenization, rolling, and annealing treatments.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Impacts of annealing treatment on the microstructure of U-Mo monolithic fuel plates

The objective of this paper is to analyze the effect of different heat treatments on the fuel microstructure and texture in laboratory scale monolithic U-Mo fuel plates. Such analyses are relevant as they could possibly inform future fabrication methods for the optimization of microstructure and of material properties to ultimately improve fuel performance during irradiation. For this reason, detail characterization including Energy x-ray dispersive spectroscopy (EDS) and electron backscattered diffraction (EBSD) techniques were applied on U-Mo plates fabricated with different heat treatments to understand the influence of fabrication on fuel microstructure. Here, U-Mo fresh fuel specimens with or without annealing treatments (homogenization and stress release annealing) after rolling were analyzed in this work. In this study for the first time EBSD was systematically used to analyze the heat treatments influence on texture present in fresh fuel monolithic U-Mo fuel plates. Such changes were connected to other known microstructural and chemical changes. In this work minimization of molybdenum concentration variation and gamma phase decomposition of the U-Mo fuel core after homogenization was observed. Also, an increase in the interaction layer of the U-Mo fuel core with the Zr interlayer diffusion barrier was observed with the UZr 2 growing up to 1 µm in thickness. Such microstructural changes were aligned to the changes in texture and grain structure. Indeed, common texture observed in body-centered cubic (BCC) metal after cold rolling (e.g., α, ξ, γ fibers) were minimized by the annealing/homogenization process. Moreover, grain structure was influenced by the fabrication route with elongated grains formed in the rolled sample and equiaxed grains found after annealing. Such features are relevant since the formation of microstructural features formed during fuel fabrication can impact fuel performance in reactor.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2015

Investigation of deformation micro-mechanisms in nickel consolidated from a bimodal powder by spark plasma sintering

Bulk polycrystalline nickel compact was processed by spark plasma sintering from heterogeneous powder consisting of a mixture of nanometer and micrometer sized particles. The consolidated samples inherited the bimodal structure of the starting powder and was composed of ~ 55 vol.% coarse-grained (with the grain size larger than 1 μm) and ~ 45 vol.% ultrafine-grained (with an average grain size of ~ 550 nm) components. The deformation mechanisms were established by EBSD, X-ray line profile analysis and in-situ TEM observations. In the ultrafine-grained volume, the deformation occurred mainly through the activation of dislocation sources emitting full or partial dislocation either from grain interior or grain boundaries. Besides dislocation activity, rolling and sliding of nanograins were also observed during deformation by in-situ transmission electron microscopy, which have a considerable contribution to the observed high strain rate sensitivity of the bimodal microstructure. The cracks formed during deformation easily propagated in the nanograin regions due to the weaker particle bonding caused by the relatively high fraction of native oxide layer on the surface of the initial nanoparticles. - Highlights: • Bulk bimodal polycrystalline Ni was processed by SPS from a heterogeneous powder. • High SRS of the flow stress was observed which enhanced ductility and strength. • In-situ TEM revealed dislocation sources inside and at the boundaries of UFGs. • Twinning, partial dislocation and NG rolling were observed at crack tip vicinity. • The high SRS pertained to both dislocation activity in CG and NG rolling.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2015

Thermal Microstructural Stability of AZ31 Magnesium after Severe Plastic Deformation

Both equal channel angular pressing and friction stir processing have the ability to refine the grain size of twin roll cast AZ31 magnesium and potentially improve its superplastic properties. This work used isochronal and isothermal heat treatments to investigate the microstructural stability of twin roll cast, equal channel angular pressed and friction stir processed AZ31 magnesium. For both heat treatment conditions, it was found that the twin roll casted and equal channel angular pressed materials were more stable than the friction stir processed material. Calculations of the grain growth kinetics showed that severe plastic deformation processing decreased the activation energy for grain boundary motion with the equal channel angular pressed material having the greatest Q value of the severely plastically deformed materials and that increasing the tool travel speed of the friction stir processed material improved microstructural stability. The Hollomon-Jaffe parameter was found to be an accurate means of identifying the annealing conditions that will result in substantial grain growth and loss of potential superplastic properties in the severely plastically deformed materials. In addition, Humphreys’s model of cellular microstructural stability accurately predicted the relative microstructural stability of the severely plastically deformed materials and with some modification, closely predicted the maximum grain size ratio achieved by the severely plastically deformed materials.

FSW↗
DOE OSTI2018

Ultrafine gradient microstructure induced by severe plastic deformation under sliding contact conditions in copper

Highlights: • Sliding contact produces a gradient microstructure by severe plastic deformation. • Nanohardness is increased strongly by grain size and dislocation hardening. • The texture components in the deformed layer correspond to pure shear. • Grain size distribution, boundary misorientation and KAM were analysed. • Strain induced effects compete with crystallisation to determine the microstructure. - Abstract: Sliding contact induces severe plastic deformation (SPD) at the surface of ductile materials and induces a microstructural gradient associated to a significant increase of hardness toward the surface. This gradient allows observing all stages of grain refinement in SPD, as illustrated here by the analysis of polycrystalline electrolytic copper tested in a coaxial tribometer. Materials tested in the cold-rolled state and after annealing were characterised by high-resolution electron backscattering diffraction and nano-indentation. The incremental plastic strain produces an ultrafine microstructure in the top layers, which gradually changes to the original size in unaffected material. In cold-rolled material, an intermediate recrystallised layer is observed. The separation of the Misorientation Angle Distribution (MAD) in a low-angle portion and a high angle portion allows characterising the accumulation of strain induced misorientation, while the Kernel Average Misorientation (KAM) provides information on the evolution of substructure at the finest levels. The results point toward a process where strain-induced effects compete continuously with recrystallisation, except for the surface layer in the cold-rolled material, where dynamic recrystallisation is dominant. Combining the information from KAM and subgrain size distribution, the measured hardness can be explained as a combination of grain size and dislocation hardening.

36 MATERIALS SCIENCE↗