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Results for “Alloy powder”

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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Investigation of the Surface Chemistry of Magnesium and Magnesium Alloy Powders

Magnesium (Mg) and Mg alloy powders are generally difficult to sinter at atmospheric pressure in inert atmospheres purportedly due to the presence of powder particle surface oxide layers. To better understand sintering of Mg and Mg alloy powders, x-ray photoelectron spectroscopy (XPS) was performed to characterize the surface chemistry of gas atomized pure Mg and Mg alloys AZ91D and WE43 powders. These results are used to quantitatively determine the surface chemistry of these powders. Additionally, equilibrium thermodynamic modeling of these Mg/Mg alloys materials exposed to oxygen down to part per billion concentrations are presented for relative comparison to experimental XPS results. Analysis of these results are intended to improve sintering of Mg and Mg alloy powder materials through more quantitative knowledge of powder surface chemistry.

25 ENERGY STORAGE↗
NASA NTRS1970

Properties of Hot Pressed Titanium Alloy Powders for Cryogenic Applications.

Evaluation of strength and toughness of hot-pressed titanium alloy powders at room and at cryogenic temperatures. The purpose was to determine how the mechanical properties of solid bodies formed from powder would compare with wrought specimens of the same size and with the same chemical analysis. It was found that of five titanium powder-making processes investigated, only the Rotating Electrode Process (REP) was capable of producing ELI-grade titanium alloy powder. Blocks hot-pressed from spherical REP powders had tensile properties equivalent to or better than those obtained from wrought bar.

Friedman, G. I.↗
DOE OSTI2023

Reduced-temperature sintering of spinel-type coatings and layers with metallic alloy powder precursors

A method of forming a spinel coating on a substrate is disclosed including the steps of coating at least a portion of the substrate with a precursor including an alloy powder, and sintering the precursor at a temperature of less than 1000 degrees Celsius to form the spinel coating. The alloy powder used for the precursor can include particles having a particle size of less than 10 micrometers. The method can be utilized to form spinel coatings as contact surfaces between electrodes and interconnects of solid oxide fuel cell (SOFC) stacks.

Zhu, Jiahong↗
NASA NTRS1976

Thermogravimetric study of reduction of oxides present in oxidized nickel-base alloy powders

Carbon, hydrogen, and hydrogen plus carbon reduction of three oxidized nickel-base alloy powders (a solid solution strengthened alloy both with and without the gamma prime formers aluminum and titanium and the solid solution strengthened alloy NiCrAlY) were evaluated by thermogravimetry. Hydrogen and hydrogen plus carbon were completely effective in reducing an alloy containing chromium, columbium, tantalum, molybdenum, and tungsten. However, with aluminum and titanium present the reduction was limited to a weight loss of about 81 percent. Carbon alone was not effective in reducing any of the alloys, and none of the reducing conditions were effective for use with NiCrAlY.

Herbell, T. P.↗
DOE OSTI2020

Study on the continuous phase evolution and physical properties of gas-atomized high-entropy alloy powders

In this study, AlCoCrFeNi high entropy alloy (HEA) powders were fabricated by gas atomization process, and the effects of annealing heat treatment on phase evolution and mechanical properties were investigated. The as-atomized powders have pure BCC phase with a spherical shape and equal composition distribution, and then the FCC and sigma phase sequentially generated after annealing. The mechanical property such as hardness was evidently enhanced, which was caused by precipitation hardening effect. After the raw powders were annealed at 600 °C, the FCC (Al–Ni) phase began to precipitate, the its phase intensity raised with the annealing temperature. Then, the sigma phase (Fe– Cr)formed as the annealing temperature reached 800 °C. Both mechanical properties and lattice constant were influenced by heating effect. According to the results, the lattice became loose with the increasing temperature. In summary, the mechanical properties and phase constitutions of gasatomized AlCoCrFeNi HEA powders can be adjusted via annealing process, resulting in precipitation hardening effect.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Processing, Microstructure, and Properties of Bimetallic Steel-Ni Alloy Powder HIP

This work explores technical feasibility in hot isostatic pressing (HIP) manufacturing of an integral bimetallic component using steel and Ni alloy powder for supercritical carbon dioxide (sCO2) turbomachinery. Lab-scale bimetallic HIP specimens using HAYNES® 282® and SS316L or SS415 powder are investigated in powder configuration, heat treatment, microstructure, and tensile properties up to 400 °C. Interdiffusion profiles at dissimilar alloy interfaces caused by HIP cycle is predicted by DICTRA simulations and validated by electron probe microanalysis (EPMA). The interdiffusion distance of most elements is around 100 μm, while C and N have a higher interdiffusion distance. Dense distribution of Ti-rich carbonitrides and alumina particles are found to decorate prior particle boundaries near joining interface on the 282 side, affecting tensile strength across interface as well as tensile failure location. A higher amount of excessive carbonitride formation near interface is observed in SS316L/282 than in SS415/282, which is consistent with the predicted greater degree of interdiffusion effect in SS316L/282. Typical HAYNES® 282® heat treatment condition is applicable to 282/SS316L and 282/SS415 combinations, resulting in a higher strength than cast CF8M and CA6NM. A pilot-scale bimetallic SS415/282 pipe is then demonstrated to show the promise of scaleup.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Sinter formation during directed energy deposition of titanium alloy powders

During directed energy deposition (DED) additive manufacturing, powder agglomeration and sintering can occur outside of the melt pool when using titanium alloy powders. Using in situ synchrotron radiography we investigate the mechanisms by which sintering of Ti6242 powder occurs around the pool, performing a parametric study to determine the influence of laser power and stage traverse speed on sinter build-up. The results reveal that detrimental sinter can be reduced using a high laser power or increased stage traverse speed, although the latter also reduces deposition layer thickness. The mechanism of sinter formation during DED was determined to be in-flight heating of the powder particles in the laser beam. Calculations of particle heating under the processing conditions explored in this study confirm that powder particles can reasonably exceed 700 °C, the threshold for Ti surface oxide dissolution, and thus the powder is prone to sintering if not incorporated into the melt pool. The build-up of sinter powder layer on deposit surfaces led to lack of fusion pores. To mitigate sinter formation and its detrimental effects on DED component quality, it is essential that the powder delivery spot area is smaller than the melt pool, ensuring most powder lands in the melt pool.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Science-Based Acceleration of the Full Value Stream for Metal Additive Manufacturing: Expedited Powder Development and Additive Manufacturing Deployment in the Areas of Ni-Base Superalloy and Custom Alloy Powders for AM (Final Report)

The overall Science-based Acceleration of the Full Value Stream for Metal Additive Manufacturing (AM): Expedited Powder Development and Additive Manufacturing Deployment (“X-P4AM”) project objective is to drastically reduce the time-to-market barriers for new additive alloys of interest in automotive and aerospace applications, through computational alloy design with rapid screening and down- selection via synthesis of candidate alloys with rapid solidification. The project will also refine the technology in high pressure gas atomization to improve the production of commercial quantities of selected powders with high powder yields and enhanced powder quality. Production of modified nickel-based superalloys and a Ni-containing alloy based on a high entropy composition, enhanced powder production methods, and optimized AM build parameterization provided critical steps in widespread adoption of AM technology for aerospace applications, in this case. The individual backgrounds and capabilities of the Parties are ideally suited to the successful execution of this work. The included work enhanced the Contractors’ AM capabilities, a core competency of the Contractors, and develop a close working relationship with the Participant in the area of nickel-based powder superalloys and custom alloys and their end use.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Science-Based Acceleration of the Full Value Stream for Metal Additive Manufacturing: Expedited Powder Development and Additive Manufacturing Deployment in the Areas of Ni-Base Superalloy and Custom Alloy Powders for AM

The overall Science-based Acceleration of the Full Value Stream for Metal Additive Manufacturing (AM): Expedited Powder Development and Additive Manufacturing Deployment (“X-P4AM”) project objective is to drastically reduce the time-to-market barriers for new additive alloys of interest in automotive and aerospace applications, through computational alloy design with rapid screening and down- selection via synthesis of candidate alloys with rapid solidification. The project will also refine the technology in high pressure gas atomization to improve the production of commercial quantities of selected powders with high powder yields and enhanced powder quality. Production of modified nickel-based superalloys and a Ni-containing alloy based on a high entropy composition, enhanced powder production methods, and optimized AM build parameterization provided critical steps in widespread adoption of AM technology for aerospace applications, in this case. The individual backgrounds and capabilities of the Parties are ideally suited to the successful execution of this work. The included work enhanced the Contractors’ AM capabilities, a core competency of the Contractors, and develop a close working relationship with the Participant in the areas of nickel-based powder superalloys and custom alloys and their end use.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Science-Based Acceleration of the Full Value Stream for Metal Additive Manufacturing: Expedited Powder Development and Additive Manufacturing Deployment in the Areas of Ni-Base Superalloy and Custom Alloy Powders for AM

The overall Science-based Acceleration of the Full Value Stream for Metal Additive Manufacturing (AM): Expedited Powder Development and Additive Manufacturing Deployment (“X-P4AM”) project objective is to drastically reduce the time-to-market barriers for new additive alloys of interest in automotive and aerospace applications, through computational alloy design with rapid screening and down- selection via synthesis of candidate alloys with rapid solidification. The project will also refine the technology in high pressure gas atomization to improve the production of commercial quantities of selected powders with high powder yields and enhanced powder quality. Production of modified nickel-based superalloys and a Ni-containing alloy based on a high entropy composition, enhanced powder production methods, and optimized AM build parameterization provided critical steps in widespread adoption of AM technology for aerospace applications, in this case. The individual backgrounds and capabilities of the Parties are ideally suited to the successful execution of this work. The included work enhanced the Contractors’ AM capabilities, a core competency of the Contractors, and develop a close working relationship with the Participant in the areas of nickel-based powder superalloys and custom alloys and their end use.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Science-based Acceleration of the Full Value Stream for Metal Additive Manufacturing (AM): Expedited Powder Development and Additive Manufacturing Deployment in the Area of Aluminum Powder Alloys

The overall Science-based Acceleration of the Full Value Stream for Metal Additive Manufacturing (AM): Expedited Powder Development (“X-P4AM”) project objective is to drastically reduce the time-to-market barriers for new additive alloys of interest in automotive and aerospace applications, through computational alloy design with rapid screening and down- selection via synthesis of candidate alloys with rapid solidification. The project will also refine the technology in high pressure gas atomization to improve the production of commercial quantities of selected powders with high powder yields and enhanced powder quality. A new aluminum (Al) alloy based on high entropy composition, enhanced powder production, and optimized AM build parameterization provided a critical step in widespread adoption of AM technology for automotive applications, in this case. The individual backgrounds and capabilities of the Parties are ideally suited to the successful execution of this work. The included work enhanced the Contractors’ AM capabilities, a core competency of the Contractors, and develop a close working relationship with the Participant in the area of aluminum powder alloys and their end use.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Recycling and Reuse of Tungsten-Rhenium Refractory Alloy Powder for Additive Manufacturing (Quarterly Progress Report - 01 April 2023-30 June 2023)

Savannah River National Laboratory in partnership with 6K Inc is working on demonstrating laser and electron-beam powder bed additive manufacturing processes of W-24Re alloy and developing powder reconditioning (deoxidation) technology via plasma spheroidization and investigating the properties and performance of additively manufactured W-24Re components produced using both virgin and recycled powders.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Science-based Acceleration of the Full Value Stream for Metal Additive Manufacturing: Expedited Powder Development in the Area of Aluminum Powder Alloys and their End Use (Final Report)

The overall Science-based Acceleration of the Full Value Stream for Metal Additive Manufacturing (AM): Expedited Powder Development (“X-P4AM”) project objective is to drastically reduce the time-to-market barriers for new additive alloys of interest in automotive and aerospace applications, through computational alloy design with rapid screening and down- selection via synthesis of candidate alloys with rapid solidification. The project will also refine the technology in high pressure gas atomization to improve the production of commercial quantities of selected powders with high powder yields and enhanced powder quality. A new aluminum (Al) alloy based on high entropy composition, enhanced powder production, and optimized AM build parameterization provided a critical step in widespread adoption of AM technology for automotive applications, in this case. The individual backgrounds and capabilities of the Parties are ideally suited to the successful execution of this work. The included work enhanced the Contractors’ AM capabilities, a core competency of the Contractors, and develop a close working relationship with the Participant in the area of aluminum powder alloys and their end use.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Investigation of In Situ and Ex Situ Passivation of Pyrophoric Uranium–Niobium Alloy Powder

This work evaluates the effectiveness of in situ and ex situ passivation methods for mitigating the pyrophoricity of uranium–6 wt.% niobium spherical powders produced via the hydride–dehydride process coupled with plasma spheroidization. Oxide layer thickness was characterized using STEM/EDX, and pyrophoricity was assessed by a UN-recommended test method, which involves directly dropping the powders in the air. In situ passivation, performed by introducing flowing oxygen during spheroidization, produced oxide layers ranging from tens to hundreds of nanometers but resulted in inconsistent pyrophoricity mitigation at lower oxygen flow rates. Ex situ passivation, achieved by slow oxygen exposure over several months, formed uniform oxide layers of approximately 20 nm and consistently mitigated pyrophoricity. Despite requiring higher bulk oxygen content, in situ passivation enables faster processing and control of oxygen, while ex situ passivation achieves superior oxide uniformity with lower oxygen incorporation. These findings highlight the trade-offs between passivation methods and provide a foundation for improving the safety and scalability of reactive metal powder production.

U-6Nb↗
NASA NTRS1986

Aluminum base alloy powder metallurgy process and product

A metallurgical method including cooling molten aluminum particles and consolidating resulting solidified particles into a multiparticle body, wherein the improvement comprises the provision of greater than 0.15% of a metal which diffuses in the aluminum solid state at a rate less than that of Mn. Aluminum containing greater than 0.15% of a metal which diffuses in the aluminum solid state at a rate less than that of Mn.

Paris, Henry G.↗
NASA NTRS1988

Processing, physical metallurgy and creep of NiAl + Ta and NiAl + Nb alloys

Powder processed NiAl + Ta alloys containing 1, 2, and 4.5 at percent tantalum and NiAl + Nb alloys containing 1 and 2 at percent niobium were developed for improved creep properties. In addition, a cast alloy with 5 at percent tantalum was also studied. Hot extrusion parameters for processing alloys with 1 and 2 at percent of tantalum or niobium were designed. The NiAl + 4.5 at percent Ta alloy could be vacuum hot pressed successfully, even though it could not be extruded. All the phases in the multiphase alloys were identified and the phase transformations studied. The Ni2AlTa in NiAl + 4.5 at percent Ta alloy transforms into a liquid phase above 1700 K. Solutionizing and annealing below this temperature gives rise to a uniform distribution of fine second phase precipitates. Compressive creep properties were evaluated at 1300 K using constant load and constant velocity tests. In the higher strain rate region single phase NiAl + 1 at percent Ta and NiAl + 1 at percent Nb alloys exhibit a stress exponent of 5 characteristic of climb controlled dislocation creep. In slower strain rate regime diffusional creep becomes important. The two phase alloys containing 2 to 5 at percent Ta and 2 at percent Nb show considerable improvement over binary NiAl and single phase alloys. Loose dislocation networks and tangles stabilized by the precipitates were found in the as crept microstructure. The cast alloy which has larger grains and a distribution of fine precipitates shows the maximum improvement over binary NiAl.

Pathare, Viren M.↗