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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 19 records

Characterization of Additively Manufactured Tungsten Heavy Alloy Material (CRADA Final Report)

LLNL and Aerojet Rocketdyne, Inc. (AR), using earlier collaborative work in powder bed printing of other materials, have been collaboratively pursuing the additive manufacture of tungsten heavy alloy (WHA) material since 2014. The goal of the project was to establish the ability to produce the LLNL developed material at the AR production facility. When accomplished, AR would produce an agreed array of test samples to technically characterize the material properties via testing. AR would conduct a portion of that testing and provide those results to LLNL. The goal of this work was to perform a trial transfer of LLNL’s WHA technology to AR

36 MATERIALS SCIENCE↗

Complex concentrated alloys: materials, methods, and techniques for manufacture

Complex concentrated alloys include five or more elements, at least one of which is ruthenium. Example complex concentrated alloys can include nickel and chromium, iron, ruthenium, molybdenum, and/or tungsten. Example complex concentrated alloys have single phase microstructure of face centered cubic (FCC) and can be homogenous. Example complex concentrated alloys can exhibit improved corrosion resistance.

Lu, Pin↗

Metallurgical alloy approach to two-dimensional supramolecular materials

Alloys are normally mixtures of metallic elements used to search for superior functional properties compared with their individual components. Although a quintessential approach to better materials in metallurgy, the concept of alloying has been expanded to other inorganic materials and covalent polymers. In this work, we report on alloy formation of small organic molecules structured as amphiphilic chromophores in water. Using X-ray scattering, microscopy, and optical spectroscopy, we unambiguously demonstrate the formation of supramolecular alloys with changes in physical, photophysical, and mechanical properties. Additionally, we identify single-crystalline, two-dimensional supramolecular polymers containing multiple molecular species, analogous to intermetallic compounds. The mechanism of alloy formation suggests the possibility of controlled growth in these supramolecular assemblies to create emergent functional structures.

36 MATERIALS SCIENCE↗

Electrical and structural properties of binary Ga–Sb phase change memory alloys

Material properties of Ga–Sb binary alloy thin films deposited under ultra-high vacuum conditions were studied for analog phase change memory (PCM) applications. Crystallization of this alloy was shown to occur in the temperature range of 180–264 °C, with activation energy >2.5 eV depending on the composition. X-ray diffraction (XRD) studies showed phase separation upon crystallization into two phases, Ga-doped A7 antimony and cubic zinc-blende GaSb. Synchrotron in situ XRD analysis revealed that crystallization into the A7 phase is accompanied by Ga out-diffusion from the grains. X-ray absorption fine structure studies of the local structure of these alloys demonstrated a bond length decrease with a stable coordination number of 4 upon amorphous-to-crystalline phase transformation. Mushroom cell structures built with Ga–Sb alloys on ø110 nm TiN heater show a phase change material resistance switching behavior with resistance ratio >100 under electrical pulse measurements. TEM and Energy Dispersive Spectroscopy (EDS) studies of the Ga–Sb cells after ∼100 switching cycles revealed that partial SET or intermediate resistance states are attained by the variation of the grain size of the material as well as the Ga content in the A7 phase. A mechanism for a reversible composition control is proposed for analog cell performance. These results indicate that Te-free Ga–Sb binary alloys are potential candidates for analog PCM applications.

Ume, Rubab (ORCID:0000000324766900)↗

Wurtzite materials in alloys of rock salt compounds

Materials with crystal structures containing tetrahedral motifs are preferable for optoelectronic applications because they often have direct band gaps and low electron effective masses. However, crystal structures of manganese chalcogenides typically contain octahedral motifs, such as in rocksalt (RS) MnS and MnSe materials. Here we experimentally show that MnS 1-x Se x alloys with tetrahedrally-bonded wurtzite (WZ) structure can form between MnSe and MnS parent compounds with octahedral RS structures, at S-rich compositions (x<0.4) and low synthesis temperatures (~300°C). The calculated mixing enthalpies of MnS1-xSex alloys in RS and WZ structures cannot explain this experimental observation, so we hypothesize that WZ stabilization may be related to smaller structure density and lower surface energy compared to RS. The resulting WZ MnS 1-x Se x alloys have 3.0-3.2 eV optical absorption onset and lower electrical conductivity (<0.0001 S/cm) compared to the parent RS compounds. These experimental measurement result are consistent with computationally predicted band gaps and effective masses.

36 MATERIALS SCIENCE↗

Physics-informed, empirically constrained machine learning for designing Fe-9Cr alloys

<span style="font-family: Calibri, sans-serif; font-size: 12pt;">Materials data analytics can be used to significantly shorten development time of specialized alloys needed for next generation energy applications. Incorporation of the domain knowledge into deep-learning graph structure via fuzzy pre-training and causal process imitation presents a viable approach to developing accurate data-driven models and reliable alloy design tools, with limited datasets. It was demonstrated that the domain knowledge-based empirical constraints not only inhibit overfitting but also allow training more accurate and reliable ML models with improved transparency of the output interpretation. In this study, alloy tensile properties were interpreted with three competing virtual-microstructure models.</span>

Romanov, Vyacheslav↗

Distinguishing Elements at the Sub‐Nanometer Scale on the Surface of a High Entropy Alloy

Materials in crystalline form possess translational symmetry (TS) when the unit cell is repeated in real space with long- and short-range orders. The periodic potential in the crystal regulates the electron wave function and results in unique band structures, which further define the physical properties of the materials. Amorphous materials lack TS due to the randomization of distances and arrangements between atoms, causing the electron wave function to lack a well-defined momentum. High entropy materials provide another way to break the TS by randomizing the potential strength at periodic atomic sites. The local elemental distribution has a great impact on physical properties in high entropy materials. It is critical to distinguish elements at the sub-nanometer scale to uncover the correlations between the elemental distribution and the material properties. Here, the use of synchrotron X-ray scanning tunneling microscopy (SX-STM) with sub-nm scale resolution in identifying elements on a high entropy alloy (HEA) surface is demonstrated. By examining the elementally sensitive X-ray absorption spectra with an STM tip to enhance the spatial resolution, the elemental distribution on an HEA's surface at a sub-nm scale is extracted. In conclusion, these results open a pathway towards quantitatively understanding high entropy materials and their material properties.

36 MATERIALS SCIENCE↗

Deformation Mechanism of Age Hardened Alloy 709 Materials

This report provides an in-depth study of the microstructures of creep-deformed Alloy 790 materials. Five specimens, all creep-tested at 600°C under 330 MPa to failure, were investigated. The creep specimens were machined from plates fabricated by different melt practices, Argon Oxygen Decarburization (AOD), or AOD followed by Electroslag remelting (ESR), and different heat treatments: 1100 or 1150°C Solution Anneal (SA), and some with additional Precipitation Treatment (PT) of 775°C for 10 hours. TEM samples were made from the gauge and the grip sections of each creep-deformed specimen. Bright-field (BF) imaging, high-angle annular dark field (HAADF) imaging, and energy dispersive x-ray spectroscopy (EDS) using a scanning transmission electron microscope (STEM) were carried out on all the samples.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Report on the FY20 Characterization of Age Hardened Alloy 709 Materials

This report provides the results on microstructural characterization of the first commercial heat of Alloy 709 plate material undergone additional age hardening treatment. In FY19, through thermodynamic-kinetic modeling and microstructural characterization, it is determined that the 775°C/10 h age-hardening treatment can promote desired precipitation on dislocations and has the potential to further improve the mechanical performance of the material. In FY20, the treatment protocol was applied to the ESR-1150°C condition, and the microstructure was then compared with the ESR-1100°C condition. It was found that the 1150°C solution annealing (SA) dramatically reduced the dislocation density compared to the 1100°C SA, resulting a smaller number density of Nb-rich fine precipitates which grow on dislocations during the age hardening treatment. Other features are very similar between the two. The effect of age hardening on creep performance is discussed. In addition, TEM characterization of a creep-ruptured sample (600°C/330 MPa) was performed. Specimens from the grip region and the gauge region was studied. The grip region specimen was effectively aged at 600°C for extended period, while the gauge region specimen was mechanically deformed at 600°C. The microstructures are very different, implying the importance of a dynamical effect on precipitation.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Alloy 709 Materials Procurement

Qualifying a new material for design and construction of elevated temperature nuclear components under Section III Division 5 of the BPVC requires measurement of a variety of properties, including tensile, creep, fatigue and creep-fatigue behavior in the relevant temperature range, and from the relevant product form, from a commercial scale heat. For the ART program the desired product form is hot rolled plate. This procurement is for a unique composition of stainless steel for which a commercial scale heat represents melting about 50,000 pounds of the alloy, resulting in about 45,000 pounds of usable plate. The Alloy 709 plate from this purchase will be provided to INL, Argonne National Laboratory and Oak Ridge National Laboratory for characterization of the relevant properties to support Code qualification.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Ultra-fast and Thick Boriding of Geothermal Casing to Enhance Reliability

Harnessing the heat that is continuously generated underneath the Earth’s crust (geothermal) is a clean and renewable source of energy. Geothermal energy can be used to heat and cool buildings, including greenhouses, and to generate electrical power. Compared to other renewable energy sources such as solar and wind, geothermal energy is more reliable because it is available all the time and versatile in its many forms of application and deployment. Nonetheless, the deployment and extensive use of geothermal energy still lags behind other renewable sources due to some technical, but mainly economic challenges. Upfront costs of geothermal power well development are relatively high. Some of this high cost is attributed to the use of expensive construction materials to ensure adequate performance during operation. For example, Inconel 625, super duplex 2507, and titanium alloy materials are used in downhole casings, piping, and other components exposed to brine solution to withstand harsh operating environments (high temperature and corrosive environments). Relatively low-cost carbon steel can be used in many of these components in geothermal power plants; however, they are susceptible to excessive corrosion, thereby limiting their useful lifespan. Ultra-fast boriding (UFB) surface treatment of carbon steel may drastically increase its corrosion resistance thereby providing a cost-effective material solution in geothermal applications. Scientists at Argonne National Laboratory (ANL) recently developed a technique to accelerate the boriding process using a high-temperature electrochemical process to produce relatively thick boride layers on various metal and alloy materials in minutes rather than the several hours it takes through the typical pack boriding process; hence, the process is designated UFB. The process uses molten borax salt at 900– 1000°C in an electrochemical cell in which the material to be borided is the cathode and a graphite plate is the anode. Continuous and durable boride layers with thicknesses of 100–300 µm have been produced on a variety of metals and alloys in one hour. Such a surface layer can indeed be a cost-effective pathway to prevent corrosion of casing materials in contact with the chemically aggressive and corrosive geothermal brine fluids.

15 GEOTHERMAL ENERGY↗

Calcium-metal alloy anode materials for reversible calcium-ion batteries

Calcium ion batteries are provided. The calcium ion batteries include a cathode, an alloying anode composed of one or more intermetallic calcium compounds in electrical communication with the cathode; and an electrolyte disposed between the anode and the cathode. The intermetallic calcium compounds are intermetallic compounds of calcium and transition metals and metalloids.

Yao, Zhenpeng↗

Machine Learning Augmented Predictive and Generative Model for Rupture Life in Ferritic and Austenitic Steels

The Larson-Miller parameter (LMP) offers an efficient and fast scheme to estimate the creep rupture life of alloy materials for high temperature applications. However, owing to poor generalizability and dependence on the constant C, which is typically not known a-priori, estimations using the Larson-Miller parameter often result in suboptimal performance for a wide range of materials. At best it is useful in comparing alloys of similar composition. In this work, three machine learning (ML) schemes were developed for rupture life prediction for 9-12% Cr ferritic-martensitic steels and austenitic stainless steels, i.e., a hierarchical model to parameterize LMP using the LMP constant C to compute rupture life, a hierarchical model to parameterize both C and LMP to compute rupture life, and a direct prediction of rupture life. Specifically, we show that the third scheme, using a gradient boosting algorithm, can be used to train ML models for very accurate prediction of rupture life in a variety of alloys (Pear-son Correlation Coefficient > 0.9 for 9-12% Cr and > 0.8 for austenitic stainless steels). In addition, the Shapley value was used to quantify feature importance, making the model interpretable by identifying the effect of various features on the model performance. Furthermore, a variational autoencoder-based generative model was built by conditioning on the experimental dataset to sample hypothetical synthetic candidate alloys from the learnt joint distribution not existing in both 9-12 % Cr ferritic-martensitic steel and austenitic stainless steel datasets. Finally, based on the predictive and generative model, a reinforcement learning strategy has been proposed to guide experimentalists into designing better heat resistant alloys.

Mamun, Md Osman G.↗

Density Functional Theory Analysis of Candidate Tritium Permeation Barriers for Vanadium Alloys as a Fusion Structural Material

Vanadium alloys are being considered as a candidate structural material for the breeder blanket component of future fusion reactors due to their good thermal conductivity, low activation, and chemical compatibility with FLiBe. However, vanadium has a high hydrogen solubility, resulting in hydrogen diffusion and trapping in the vanadium structural alloy and lower than expected tritium breeding ratios. To mitigate the permeation of hydrogen into the structural alloy, a tritium permeation barrier will be coated onto the vanadium alloy. Multiple materials have been proposed as candidate tritium permeation barriers, but the extent to which each of these materials impacts hydrogen diffusion and trapping is still unknown. In this project, we perform atomic-scale calculations to narrow down the list of potential tritium permeation barrier candidates and to understand the mechanisms through which hydrogen diffusion is affected in these materials.

36 MATERIALS SCIENCE↗

Boosting Superior Lithium Storage Performance of Alloy-Based Anode Materials via Ultraconformal Sb Coating–Derived Favorable Solid-Electrolyte Interphase

Alloy materials such as Si and Ge are attractive as high-capacity anodes for rechargeable batteries, but such anodes undergo severe capacity degradation during discharge-charge processes. Compared to the over-emphasized efforts on the electrode structure design to mitigate the volume changes, understanding and engineering of the solid-electrolyte interphase (SEI) are significantly lacking. This work demonstrates that modifying the surface of alloy-based anode materials by building an ultraconformal layer of Sb can significantly enhance their structural and interfacial stability during cycling. Combined experimental and theoretical studies consistently reveal that the ultraconformal Sb layer is dynamically converted to Li 3 Sb during cycling, which can selectively adsorb and catalytically decompose electrolyte additives to form a robust, thin, and dense LiF-dominated SEI, and simultaneously restrain the decomposition of electrolyte solvents. Hence, the Sb-coated porous Ge electrode delivers much higher initial Coulombic efficiency of 85% and higher reversible capacity of 1046 mAh g -1 after 200 cycles at 500 mA g -1 , compared to only 72% and 170 mAh g -1 for bare porous Ge. The present finding has indicated that tailoring surface structures of electrode materials is an appealing approach to construct a robust SEI and achieve long-term cycling stability for alloy-based anode materials.

25 ENERGY STORAGE↗

Multicaloric MnNiSi alloys

A multicaloric alloy material combines two isostructural compounds, the first compound being MnNiSi and the second compound being either MnFeGe or CoFeGe, each such compound having extremely different magnetic and thermo-structural properties. The resulting alloy material (MnNiSi)1-x(MnFeGe)x or (MnNiSi)1-x(CoFeGe)x possesses extraordinary magnetocaloric and/or barocaloric properties with an acute sensitivity to applied pressure and no appreciable magnetic hysteresis losses.

Samanta, Tapas↗

Report Documenting Activity for Second Alloy 709 Commercial Heat

SUMMARY Qualification of the advanced austenitic stainless steel material Alloy 709 for use in Section III Division 5 of the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code is being pursued by the US Department of Energy Advanced Reactor Technology Program. Qualification of this alloy will allow its use in design and construction of components for elevated temperature nuclear reactor systems. Code qualification requires extensive characterization of three commercial scale heats of the alloy. This report describes progress in procuring the second of three required heats of Alloy 709 plate from ATI Flat Rolled Products.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗