Metallurgy Commons^™

Microstructure-Based High Temperature Processing And Failure Analyses Of Engineering Alloys Under Complex Conditions, Dong Han

Doctoral Dissertations

From traditional petrochemical applications to contemporary manufacturing techniques, advanced structural materials are subjected to intricate thermomechanical and environmental conditions. In these engineering domains, high-temperature deformation plays a pivotal role, profoundly influencing the ultimate outcomes of industrial applications. Nevertheless, the underlying mechanisms of this deformation remain elusive, largely due to the absence of a microstructure-based mechanistic understanding of high-temperature processing and failure of materials.

This dissertation endeavors to comprehensively examine these mechanisms through computational methodologies, focusing on three quintessential topics: grain boundary cavitation failures (2 examples: stress relaxation cracking (SRC) and grain size dependence), high-temperature hydrogen attack (HTHA), and additive friction …

Stress Relaxation Cracking In 347h Austenitic Steel Weldments Under Various Heat Treatments: Experiments And Modeling, Yi Yang

Doctoral Dissertations

347H austenitic stainless steel exhibits exceptional creep and corrosion resistance, rendering it an exemplary candidate for pipeline materials, particularly in mid- to high-temperature working conditions. However, due to constraints in component dimensions, welding has been chosen as the preferred method for joining pipeline systems extensively employed in nuclear power plants, fossil fuel plants, and petrochemical companies. The welding process entails the accumulation of residual stress during the cooling stage, along with the introduction of microstructure evolution. Moreover, the residual stress field and microstructure continuously evolve under service conditions, thereby intensifying the susceptibility of crack initiation and propagation. The initial residual …

Investigation Of Microstructure And Mechanical Behavior Of Novel Powder-Extruded Al-Ce-Mg Alloys, Mairym Vazquez

Doctoral Dissertations

Pursuing advanced structural materials with enhanced performance, reduced weight, and lower costs is a constant endeavor in the aerospace and automotive industries. Conventional structural alloys, such as cast irons, carbon steels, and titanium alloys, have strength, weight, and cost limitations. Aluminum-based alloys, known for their lightweight and high strength, have gained popularity in these industries. This dissertation focuses on investigating microstructure and mechanical behavior of novel powder-extruded Al-Ce-Mg alloys as potential candidates for high-performance structural materials.

This research explores using powder extrusion, a well-established forging methodology in the steel industry, to produce Al-Ce-Mg alloys with improved properties and aims to …

Refractory High-Entropy Alloys: Design, Fabrication, Characterization, And Nanoparticle Synthesis, John Hutson Whitlow

Masters Theses

High-Entropy Alloys have been a highly researched area of metals ever since their introduction in 2004 by Brian Cantor and Jien-Weh Yeh. In the continued research of High-Entropy Alloys (HEAs), a specific area concerning Refractory High-Entropy Alloys (RHEAs) has emerged for their high-temperature applications. Although RHEAs have maintained high strength and toughness at high temperatures, their low ductility still needs to be addressed. A dataset was created to find correlations between various characteristics of RHEAs and their composition. A set of seven compositions were selected and fabricated. Mechanical tests were run on the seven compositions, and a proposal was written …

Kinetics And Phase Stability Of Nano-Scale Precipitates In Fe-Based Binary Alloys During Ion Irradiations, Yajie Zhao

Doctoral Dissertations

Due to the high void-swelling resistance and good mechanical, thermal and chemical properties, FeCr based ferritic-martensitic steels are promising structural materials in future nuclear reactors. However, they suffer from the well-known “475 °C embrittlement” phenomenon due to formation of Cr-rich alpha prime (α’) precipitates. Despite the extensive observation of α’ after neutron irradiations, α’ formation was seldom reported after high dose rate ion irradiations.

In this study, high purity FeCr alloys with Cr concentrations of 5-18% were irradiated by 8 MeV Fe ions at -123 °C to 450 °C, 10^-5 – 10^-3 dpa/s to mid-range doses of 0.37-3.7 …

Fabrication, Thermophysical, And Mechanical Properties Of Cermet And Cercer Fuel Composites For Nuclear Thermal Propulsion, Neal D. Gaffin

Doctoral Dissertations

Nuclear thermal propulsion (NTP) utilizes nuclear fission to double the efficiency of
in-space propulsion systems compared with traditional combustion rocket systems.
NTP systems are limited primarily by the fuel material choice, due to the extreme
conditions they will need to endure, including temperatures up to 3000 K, multiple
thermal cycles with rapid heating and cooling, exposure to hot flowing hydrogen,
large thermal gradients, and high neutron flux. Particle based fuels, namely ceramic-
metallic (cermet) and ceramic-ceramic (cercer) composites are both promising fuel
element material candidates for NTP. Given the high temperature nature, these
materials are difficult to fabricate and very …

Fundamental Understanding Of The Transient Melt Pool Dynamics, Solidification Kinetics And Build Texture In Spot-Melt Additive Manufacturing Of Ti-6al-4v, Rakesh Rajaram Kamath

Doctoral Dissertations

The overarching goal of this dissertation is to better understand the underlying process-structure relationships in play during the implementation of a spot melt strategy for metal additive manufacturing, which has become a popular alternative to the conventional raster melt strategy for site-specific microstructure control. In the first part of this dissertation, the effect of a spot melt strategy on the solidification texture, variant selection, phase fraction, and their variations along the build height of an E-PBF Ti-6Al-4V is investigated in comparison to a conventional linear melt strategy using high-energy synchrotron x-ray diffraction. In spite of the thermal excursions involved, the …

Effects Of Plastic Deformation From Ultrasonic Additive Manufacturing, Michael Pagan

Doctoral Dissertations

Nuclear energy technology can be exponentially advanced using advanced manufacturing, which can drastically transform how materials, structures, and designs can be built. Ultrasonic Additive Manufacturing (UAM) represents one of the four main additive manufacturing methods, although it is also the newest. As UAM technology and applications develop, a fundamental understanding of the bonding mechanism is crucial to fully realize its potential. Currently UAM bonding is considered to occur through breaking down surface asperities and removing surface oxides. Plastic deformation occurs although its role is currently unclear. This research analyzes material configurations in a variety of geometries, with similar and dissimilar …

Design And Evaluation Of A Unique Weighted-Sum-Based Anger Camera, Matthew W. Seals

Masters Theses

Anger camera imaging technology has become widely popular for neutron diffraction imaging due to recent shortages in Helium-3 (He-3). Research into neutron diffraction optimized Anger camera by the Oak Ridge National Laboratory (ORNL) detectors group has provided an alternative to He-3 Tube-based detectors with a high-resolution Anger camera. However, the cost of these high-resolution Anger camera technology can make it less attractive than He-3 tubes when a large Field of View (FOV) is desired. Currently, there is a need for a lower-cost alternative to this high-resolution anger camera. Further applications for Anger camera have become of interest with the advent …

Fundamentals Of Cavity Formation In Α-Fe And Fe-Cr Alloys, Yan-Ru Lin

Doctoral Dissertations

Ferritic-martensitic steels are attractive candidate materials for fusion and advanced fission reactors primarily due to their low swelling characteristic, attractive thermo-mechanical properties, and the potential for development of nanostructured ferritic alloys. However, significant discrepancies exist regarding the effect of solutes and irradiation temperature on cavity swelling under ion versus neutron irradiation conditions. Several mechanisms have been proposed that may affect cavity swelling, but no general theory or model has received complete acceptance to explain these phenomena.

To better understand the formation of cavities in ferritic steels, we have performed multi-temperature (400-550°C) single-beam and simultaneous dual-beam irradiations (ex-situ and in-situ) on …

Development Of A Novel Casting Alloy Composed Of Aluminum And Cerium With Other Minor Additions, Zachary Cole Sims

Doctoral Dissertations

Eutectic casting alloys of aluminum and cerium are a recent discovery and early research describes an alloy with great potential to meet the growing demand for a lightweight, economical, high specific strength material for use in high-temperature or extremely corrosive environments. The broad application of aluminum alloys across industry sectors is driven by their collection of balanced properties including economical cost, high specific strength, and flexibility of their production pathways. Additionally, their high corrosion resistance makes them a good choice for structural materials. Despite this, the push to use aluminum alloys in ever more extreme environments with higher temperatures, stresses, …

Design And Development Of Strong And Ductile Single Bcc Refractory High-Entropy Alloys For High-Temperature Applications, Chanho Lee

Doctoral Dissertations

The objectives of this proposed study are to (1) design and develop single BCC phase refractory high-entropy alloys (HEAs) for the high-temperature applications, (2) investigate the deformation mechanisms of refractory HEAs, (3) improve an integrated approach, coupling focused experiments and theoretical modeling, to design, discover, and develop HEAs, and (4) understand the alloy design-microstructure-property-performance links underlying the mechanical behavior of refractory HEA systems for gas-turbine applications

A traditional alloy system generally includes one or two principal elements that form the matrix with other additional elements, e.g., iron or aluminum alloys, to strengthen some specific properties, such as strength and corrosion …

Cracking And Earing Phenomenon In Deep-Drawn Stainless Steel Alloys: Role Of Transformation Kinetics, Microstructure, And Texture, Peijun Hou

Doctoral Dissertations

The enhancement of formability of advanced high-strength TRIP-assisted steel alloys is a challenging assignment for industrial application due to the cracking phenomenon. The critical factor governing the cracking behavior is residual-stress concentration resulting from the inhomogeneous plastic deformation and microstructural evolution during the forming processes. Martensitic phase transformation kinetics, constituent phases, and crystallographic texture in TRIP-assisted steel alloys are correlated to the microstructure evolution, resulting in phase-specific stress concentration. In the current study, we are aiming at understanding the fundamental mechanisms responsible for the cracking phenomenon and thus improving the formability of TRIP-assisted steel alloys. Four stainless steel (SS) alloys …

Experimental And Computational Investigation Of High Entropy Alloys For Elevated-Temperature Applications, Haoyan Diao

Doctoral Dissertations

To create and design novel structural materials with enhanced creep-resistance, fundamental studies have been conducted on high-entropy alloys (HEAs), using (1) thermodynamic calculations, (2) mechanical tests, (3) neutron diffraction, (4) characterization techniques, and (5) crystal-plasticity finite-element modeling (CPFEM), to explore future candidates for next-generation power plants.

All the constituent binary and ternary systems of the Al-Cr-Cu-Fe-Mn-Ni and Al-Co-Cr- Fe-Ni systems were thermodynamically modeled within the whole composition range. Comparisons between the calculated phase diagrams and literature data are in good agreement. The Al_xCrCuFeMnNi HEAs have disordered [face-centered-cubic (FCC) + body-centered-cubic (BCC)] crystal structures. Excessive alloying of the Al …

Microstructure Control And Correlation To Creep Properties In Grade 91 Steel Weldment After Thermo-Mechanical Treatments And An Fe-30cr-3al Alloy Strengthened By Fe2nb Laves Phase, Benjamin Allen Shassere

Doctoral Dissertations

Type IV cracking in weldments of steel pipes after creep deformation is a concern in modern fossil-fueled power plants. Two possible methods for minimizing or eliminating Type IV cracking will be discussed. The first method alters the initial microstructure of typical Grade 91 steel base metal before welding, while the second provides baseline microstructure characteristics and creep performance of a new alloy that is strengthened by the intermetallic Fe2Nb Laves phase. The initial microstructure of the Grade 91 steel can be controlled by Thermo-Mechanical Treatments, which aids in precipitation of fine (5-10 nm) MX particles in austenite before transformation to …

Microstructure And Creep Deformation Behavior Of A Hierarchical-Precipitate-Strengthened Ferritic Alloy With Extreme Creep Resistance, Gian Song

Doctoral Dissertations

Hierarchical NiAl [nickel-aluminium compound]/Ni₂TiAl [nickel-titanium-aluminum compound] or single Ni₂TiAl-precipitate-strengthened ferritic alloys have been developed by adding 2 or 4 weight percent [wt. %] of Ti [titanium] into a previously-studied NiAl-precipitate-strengthened ferritic alloy. A systematic investigation has been conducted to study the interrelationships among the composition, microstructure, and mechanical behavior, and provide insight into deformation micro-mechanisms at elevated temperatures.

The microstructural attributes of hierarchical or single precipitates are investigated in the Ti-containing ferritic alloys. Transmission-electron microscopy in conjunction with the atom-probe tomography is employed to characterize the detailed precipitate structure. It is observed that the 2-wt.-%-Ti alloy …

Microstructures And Mechanical Behavior Of Nial-Strengthened Ferritic Alloys At Room And Elevated Temperatures, Zhiqian Sun

Doctoral Dissertations

In order to improve the thermal efficiency and decrease the greenhouse gases emission, it is required to increase the steam temperature and pressure in fossil-energy power plants. In the United States, research has been performing in order to push steam temperature to 760 Celsius degree and steam pressure to 35 MPa. However, the highest operational temperature for current commercial heat-resistant ferritic steels is ~ 620 Celsius degree. In this sense, new advanced ferritic alloys with better creep resistance are needed, considering such service conditions in next-generation ultra-supercritical fossil-energy power plants.

Coherent B2-ordered NiAl-type precipitates have been employed to reinforce the …

Molecular Dynamics Simulation Of Irradiation Damage In Multicomponent Alloys, Wei Guo

Doctoral Dissertations

The development of the generation IV reactors calls for radiation resistant materials. This thesis proposes that the newly developed single phase solid solution of high-entropy alloys (HEAs) can be such candidates. HEAs can undergo the crystalline to amorphous to crystalline (C-A-C) transitions under radiation. The radiation induced amorphous structure is a highly radiation resistant medium as shown by previous studies, and it further transforms to crystalline phases without much structural defects. In this thesis, by reviewing the formation rules of solid solutions and amorphous metallic glasses, it is suggested that the atomic size plays a key role affecting the C-A-C …

Studies Of High Temperature Hydrogen Related Damage In Welded Carbon Steel Components Used In Refineries, Maneel Bharadwaj

Masters Theses

Five materials encompassing various grades of carbon steel were received from retired and ex-service petroleum refinery equipment for root-cause evaluation of High Temperature Hydrogen Attack (HTHA) damage at UTK. These materials were submitted by three contributors: Irving Oil Refinery (IOR #1110-2), Valero (#67 & #1252134), and Phillips 66 (#555-S1 & #555-S2) on behalf of American Petroleum Institute (API). These materials originated from various flange-to-pipe welded components that were exposed in hydrogen pressure environment at elevated temperatures (> 640°F and >70 psia).

A singular crack originating at the flange inside surface just outside of the visible HAZ was observed in IOR …

Influence Of Texture And Grain Size On The Plastic Anisotropy In A Wrought Mg Alloy: Synchrotron X-Ray Diffraction And Visco-Plastic Self-Consistent Modeling, Yi Wang

Doctoral Dissertations

The combined effects of texture and grain size on the yielding and hardening behavior in a hot-rolled AZ31B Mg alloy were studied by using synchrotron x-ray diffraction and visco-plastic self-consistent (VPSC) simulation methods.

First, the influence of texture on Hall-Petch relationships (namely, critical resolved shear stresses and hardening parameters) in a Mg alloy was investigated to establish a constitutive basis for the VPSC simulation.

Then, the changes in dominant deformation mechanisms (basal, prismatic, and pyramidal slip as well as extension twin) and their relative interactions were studied systematically as a function of the initial texture using a VPSC scheme. The …

Fatigue, Fracture, And Environmentally-Assisted Behavior Of Advanced Engineering Materials, Zhi Tang

Doctoral Dissertations

The objective of the present study is to provide a fundamental understanding of fatigue, fracture, and environmentally-assisted behavior of high-entropy alloys (HEAs). The work involves fatigue, fracture, and environmentally-assisted behavior of a new kind of advanced engineering materials, called HEAs. Three tasks are studied: (1) microstructures and fracture mechanisms of HEAs, (2) fatigue failure and life prediction of HEAs, and (3) corrosion and environmentally-assisted behavior of HEAs.

In the first task, microstructural stability and fracture mechanism of the AlCoCrFeNi alloy are studied and compared with thermodynamic calculations. In the second task, high-cycle fatigue-failure mechanisms of the cold-rolled Al0.5CoCrCuFeNi alloy are …

Reverse Engineering Of Reciprocating Saw, Nicholas Alexander Cavopol, Candice Kinsler, Carly Jania, Joseph Richard Creekmore

Chancellor’s Honors Program Projects

No abstract provided.

Investigation Of The Phase Transformation Kinetics And Texture Evolution In A Trip Steel Under Complex Loads, Ercan Cakmak

Doctoral Dissertations

The martensitic phase transformation kinetics and its relation with texture evolution and deformation/transformation microstructures under complex loading conditions were investigated in a 304L stainless steel that exhibits the transformation induced plasticity (TRIP) effect when strained at ambient temperature. The applied load paths included torsional and biaxial deformation scenarios including simultaneous biaxial torsion/tension and torsion/compression as well as stepwise deformation of tension followed by torsion. Synchrotron x-ray and electron back-scatter diffraction techniques were used to investigate the phase transformation-microstructure-texture evolutions relations.

Under torsional deformation, the inhomogeneous distribution of martensite phase fractions were recorded through the radius of solid cylindrical specimens consistent …

High Energy Synchrotron X-Ray Study Of Fatigue Damage In Amorphous And Polycrystalline Engineering Alloys, Chih-Pin Chuang

Doctoral Dissertations

The dissertation summarizes a series of studies on the fatigue damage of both amorphous and crystalline engineering alloys. The attention focuses on the utilization of synchrotron x-ray scattering related techniques for advanced material characterizations. In the first part of the research, critical issues regarding the mechanical response and structural evolution of Bulk-Metallic Glasses (BMGs) in the elastic region are addressed. The effects of cyclic-loading on the microstructures of an amorphous alloy are investigated, aiming to provide better mechanistic understandings of fatigue damage in BMGs. The second part of the research focuses on the characterization method based on two-dimensional X-ray diffraction …

Understanding Mechanical And Fatigue Behavior Of A Wrought Magnesium Alloy Using In-Situ Neutron And Synchrotron X-Ray Diffraction, Wei Wu

Doctoral Dissertations

Magnesium (Mg) alloys have received great attentions in the past several decades, due to their unique properties of low density, high strength-to-weight ratio, and high specific stiffness. Previous work on fatigue behavior of Mg alloys typically relies on ex situ microstructural characterization and crack-growth monitoring with replica techniques. The primary challenge is thus the lack of an in situ, non-destructive measurement on microstructural length scales, which prevents us from linking the stress analyses (top-down point of view) to the failure mechanisms on inter- and intra-granular scales (bottom-up point of view). A unique opportunity that resolves many of these difficulties …

Processing, Microstructures, And Mechanical Behavior Of High-Entropy Alloys, Zhi Tang

Masters Theses

Recently, high-entropy alloys (HEAs) have attracted increasing attentions because of their unique compositions, microstructures, and adjustable properties. In this work, microstructure and phase composition of the AlCoCrFeNi high-entropy alloy (HEA) were studied in as-cast and heat-treated conditions. Using a combination of Electron Backscatter Diffraction (EBSD), X-ray energy spectroscopy analysis, and synchrotron X-ray diffraction techniques, two nonequilibrium phases were identified in the as-cast condition: BCC_A2 and B2. Long-term heat treatment transformed these nonequilibrium phases into four equilibrium phases: FCC_A1, BCC_A2, B2, and σ [sigma] phase. The electron microscopic results were consistent with thermodynamic simulations of the equilibrium …

Development And Use Of A Simple Test Method To Evaluate Reheat Cracking Sensitivity In The Weld Deposit Region Of A Submerged Arc Weld, Maxwell Calder Trent

Masters Theses

Several fabricators have recently noted the occurrence of reheat cracking in the weld deposits of 2¼[ two and one fourth]Cr‑1Mo‑¼[one fourth]V (22V) during the fabrication of pressure vessels used in the petrochemical industry. Due to increased oversight now required during fabrication of already expensive pressure vessels, studies have commenced worldwide in an effort to identify root causes and formulate mitigating actions to weld reheat cracking issues. The Materials Joining Group (MJG) at the University of Tennessee at Knoxville (UTK) have adapted an existing reheat cracking test originally developed for use with alloys similar to 22V. This original C‑Ring test was …

Metallurgical Effects On Long-Term Creep-Rupture In A New Nickel-Based Alloy, John P Shingledecker

Doctoral Dissertations

A series of creep-rupture studies were conducted on a new nickel-based alloy, Inconel Alloy 740, for use in Advanced Ultrasupercritical (A-USC) Steam boiler applications. The research quantitatively showed, for the first time, that the formation of a small amount of eta phase during long-term creep testing at 750 degrees Celsius does not degrade the rupture strength or ductility of the alloy. A unique full-scale pressurized tubular creep test was conducted, and a new analysis methodology was developed to evaluate the effect of cold-straining on the creep performance of tube bends made from the alloy. The results showed that 15% cold-work …

Computational And Experimental Study Of Structure-Property Relationships In Nial Precipitate-Strengthened Ferritic Superalloys, Shenyan Huang

Doctoral Dissertations

Ferritic superalloys strengthened by coherent ordered NiAl B2-type precipitates are promising candidates for ultra-supercritical steam-turbine applications, due to their superior resistance to creep, coarsening, oxidation, and steam corrosion as compared to Cr ferritic steels at high temperatures. Combined computational and experimental tools have been employed to investigate the interrelationships among the composition, microstructure, and mechanical behavior, and provide insight into deformation micromechanisms at elevated temperatures.

Self and impurity diffusivities in a body-centered-cubic (bcc) iron are calculated using first-principles methods. Calculated self and impurity diffusivities compare favorably with experimental measurements in both ferromagnetic and paramagnetic states of bcc Fe. The calculated …

Shear-Band Formation And Thermal Activation In Metallic Glasses, Lu Wang

Doctoral Dissertations

Metallic glasses (MGs) usually have high strength, high hardness and high elastic strain limit. However, the deformation mode and mechanism in metallic glasses are radically different from those in conventional crystalline materials with a long-range ordered structure. For crystalline materials, the intrinsic relationship between their mechanical properties and crystal structures has been well described by dislocation theory. In contrast, for amorphous materials, theories on the structures and controlling factors of localized shear-band formation are far from being complete.

In this thesis, shear-banding behavior of MGs under nanoindentation was first reviewed. The hardness of MGs was found to be independent on …