Metallurgy Commons^™

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 …

Surface Corrosion Response Of Al Alloys A383 And Aural 2 With Ce Additions In Aqueous Nacl And Salt-Fog Environments, Michael James Thompson

Masters Theses

Copper is commonly used in aluminum alloys to increase its strength by solid solution and precipitation strengthening, however, the corrosion resistance is inversely related to the amount of copper in the alloy. Over 70 percent of material used to produce aluminum alloys in the US come from recycled (secondary) alloys, many of which have a copper content of more than one percent by weight. Alloys with tightly controlled tolerances, where copper is seen as an impurity, are unable to utilize many of the recycling feedstock without adding newly processed (primary) aluminum to dilute impurities to within specifications. Primary aluminum is …

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 …

Assessing Mechanical Performance Of Dissimilar Steel Systems Made Via Wire-Arc Additive Manufacturing, Obed Daniel Acevedo

Masters Theses

Hot stamping is part of a specific type of metalworking procedure widely used in the automotive industry. This research seeks to help make hot stamp tooling component production more cost-effective by using large-scale additive manufacturing. Additive manufacturing can produce dissimilar steel components that can be more cost-effective and time-efficient and allow for complex geometries to be made. A dissimilar steel system consisting of 410 martensitic stainless steel and AWS ER70S-6 mild steel is proposed to make hot stamps, making them more cost-efficient. However, the material interface's mechanical behavior in 410SS-mild steel additively manufactured material systems is not well understood. This …

Evaluation Of The Potential For Weld-Related Cracking In Cast 20cr-32ni-1nb Heat-Resistant Stainless Steel, John William Bohling

Masters Theses

Steam reforming of hydrocarbons is an important process for the production of hydrogen for industrial needs, such as ammonia synthesis. Due to the high temperature conditions (700 °C–900 °C), reformer furnace components require materials with excellent creep properties and thus highly alloyed austenitic stainless steels are typically employed. For reformer outlet manifolds, a cast, heat-resistant stainless steel with the composition 20Cr-32Ni-1Nb (ASTM A351 Grade CT15C) is widely used. However, after service exposure this alloy exhibits problems with liquation cracking in the base metal heat-affected zone (HAZ) during repair welding. In the work presented herein, two heats of material from centrifugally-cast …

Magnetron Sputtering And Corrosion Of Ti-Al-C And Cr-Al-C Coatings For Zr-Alloy Nuclear Fuel Cladding, Devin Alan Roberts

Masters Theses

The disaster at the Fukushima Daiichi Nuclear Power Plant in March 2011 bought renewed focus to the issue of corrosion in nuclear fuel cladding applications. This thesis reports on the background behind these issues, the investigation strategy, and the analysis of experiments focused on mitigating oxidation of Zr-alloy fuel cladding. This thesis seeks to develop magnetron sputtered Ti-Al-C and Cr-Al-C coatings for Zr-alloy substrates and characterize the as-deposited and corroded samples.

Ti-Al-C and Cr-Al-C coatings were deposited onto ZIRLO, Si, and Al₂O₃ [Aluminum Oxide] substrates under various sputtering conditions. A combinatorial sputtering method was employed to refine …

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 …

An Evaluation Of Void Formation In Ex-Service And Creep Tested Hp Alloy Tubing Used For Hydrocarbon Reforming, Zane William Fox Palmer

Masters Theses

HP alloy tubing is commonly used in petroleum reforming facilities for its high temperature strength and resistance to corrosion. Unfortunately, the tubes can experience failure during service caused by the formation of voids in the tube wall brought on by creep stress generated by the pressure differential and thermal gradient between the inside and outside diameters of the tube. The purpose of this project was to analyze the formation of voids in eight ring sections, each from a different ex-service tube, from a total of three different manufacturers (identified as M1, M2, and M3). Further analysis of the ex-service tubes …

Deformation Behavior Of Bulk Metallic Glasses And High Entropy Alloys By Nanoindentation, Yuting Li

Masters Theses

Nanoindentation has become a powerful tool in the measurement of the mechanical properties of diverse materials, such as metallic materials, polymer materials, and even biomaterials.

In this thesis, three types of Zr-based bulk metallic glasses (BMGs) were investigated by nanoindentation. Our work focuses on the characterization of the hardness, the reduced modulus, and the deformation behavior under different indentation conditions. The study of the hardness and the reduced modulus is to access the effect of the indentation load on deformation behavior and to determine the inhomogeneous deformation. The morphological profiles of the residual indentation on the surface of the specimen …

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 …

Fatigue Behavior Of High-Entropy Alloys, Michael Alexander Hemphill

Masters Theses

Research was performed on the Al₉Co_18.2Cr_18.2Cu_18.2Fe_18.2Ni_18.2 [subscripts atomic percent] and Al_7.5Cr_22.5Fe₃₅Mn₂₀Ni₁₅ high-entropy alloys (HEAs) in an attempt to study their fatigue behavior. The present investigation shows encouraging fatigue-resistance characteristics due to their high fatigue lives of various samples at relatively high stresses. The current results indicate that the fatigue behavior of HEAs compares favorably to many conventional alloys, such as steels, titanium alloys, and advanced bulk metallic glasses with a fatigue-endurance limit of the Al₉Co_18.2Cr_{18.2 …}

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 …

Effect Of Moisture Absorption On The Sinter Quality Of Central Solenoid (Cs) Coil Pack, Zeshaan Sher Mohammed

Masters Theses

Fusion energy has been said to be the solution to all the world’s energy problems. The International Thermonuclear Experimental Reactor (ITER) is the flagship project to demonstrate the feasibility of fusion energy. The Central Solenoid (CS), an important component of the reactor, is needed to induce plasma current, initiate, ramp-up, ramp-down, and sustain plasma in a very controlled manner. In order to achieve this, the CS coil packs must be manufactured under controlled conditions. The CS conductor is an advanced cable-in-conduit Nb3Sn superconductor. The CS cable will be made in long continuous sections but with thousands of meter of cable …

Elastic And Magnetic Properties Of Tb6fe(Sb,Bi)2 Using Resonant Ultrasound Spectroscopy., David Michael Mccarthy

Masters Theses

Tb6FeSb2 and Tb6FeBi2 are novel rare earth compounds with little prior research. These compounds show high and variable curie temperatures for rare-earth compounds. This has lead to a literature review which includes the discussion of: elasticity, resonance, and magnetism. This review is used to discuss the theory and methodology which can relate these various properties to each other. Furthermore, synthesis, x-ray analysis, and RUS sample preparation of Tb6FeSb2 and Tb6FeBi2 were completed.

Resonant Ultrasound Spectroscopy (RUS) elastic studies were taken for Tb6FeSb2 and Tb6FeBi2 as a function temperature from 5-300K, in various magnetic fields ranging from 0-9T. Tb6FeSb2’s and Tb6FeBi2’s …

The Weldability Of Cr-Mo Steels For Fossil Energy Applications, Mark W. Richey

Masters Theses

This research program was undertaken to provide fundamental and basic metallurgical information on the behavior of the heat-affect zone (HAZ) in Cr-Mo steel welds, as well as practical information on their relative weldability. The principal work was the evaluation of the stress-relief cracking (SRC) and hydrogen-assisted cracking (HAC) susceptibility of Cr-Mo steels ranging in Cr content from 2 1/4%-12%. Differences in observed cracking behavior were contrasted with differences in composition, on-cooling transformation behavior and weld microstructure.

The test methods were varied to investigate the effect of preheat, post-weld heat treatment (PWHT) , metallurgical structure and restraint (externally applied) on the …

The Origin And Nature Of Flash Weld Defects In Iron-Nickel Base Superalloys, Ronald William Gunkel

Masters Theses

The purpose of this investigation is to determine the nature and morphology of weld defects on the fracture surfaces of flash welded high temperature, high strength alloys. Emphasis is on the material-related phenomena instead of the more commonly studied welding process variables.

Samples were fractured in a slow bend test using three-point loading. The resulting fracture surfaces were examined in a scanning electron microscope, and elemental analysis of distinctive fracture features was determined using the ancillary energy dispersive x-ray system. When the fracture surface analyses were completely documented, metallographic sections through distinctive features were examined using a bench metallograph.

The …