Ferrochromium from Domestic Lateritic Chromites

As part of its effort to devise suitable technology for processing low-grade domestic materials and recycling wastes, the U.S. Bureau of Mines has evaluated the feasibility of smelting a chromite concentrate derived from residues generated by the processing of nickel and cobalt from domestic later-ites. The product sought was a high-carbon ferrochromium suitable for stainless- and alloy-steel production. The concentrate was blended with re-ductants and fluxing constituents and was smelted under submerged arc conditions in a laboratory-scale, single-phase ac electric arc furnace. The results revealed that metallurgical-grade coke provides the best quality product. High-carbon ferrochromium, which met ASTM specifications except for phosphorus and sulfur, was obtained. Agglomeration of the charge materials was not required.     

Effect of Aging Treatments on the Mechanical and Corrosive Behaviors of Spray-Formed 7075 Alloy

Mechanical properties, microstructure, exfoliation corrosion (EXCO), and intergranular corrosion (IGC) behaviors of the spray-formed 7075 aluminum alloy after T6, T73, retrogression (R), and re-aging (RRA) treatment, respectively, were studied by using tensile tester, transmission electron microscope, and scanning electron microscope. The results show that the T6 process can increase the ultimate tensile strength (UTS) up to 760 MPa, while it decreases the elongation, the EXCO, and the IGC resistance of the alloy. The T73 process can improve elongation, the EXCO, and the IGC resistance of the alloy. The corrosion resistance of the alloy can also be improved by R and RRA processes with retrogression times increase. The tiny precipitated phases distributed homogeneously in the matrix can increase the UTS. The close-connected discrete grain boundary phases (GBP) and the narrow precipitate free zones (PFZ) will lower the elongation, the EXCO, and the IGC resistance of the alloy. Contrarily, the discrete GBP and wide PFZ can improve the elongation, the EXCO, and the IGC resistance of the alloy. The EXCO and the IGC behaviors for the spray-formed 7075 alloy after different aging treatments have been established according to the standards of ASTM G34-2001 (2007) and ASTM G110-1992 (2009).     

A Combined Thermodynamic/Kinetic Modeling Approach to Predict SiC Recession Due to SiO2 Scale Volatility Under Combustion Environments

A computational approach, which targets on the prediction of SiC recession caused by SiO₂ scale volatility under combustion environments, was developed in this study. In this approach, thermodynamic calculation was integrated with a gaseous-diffusion model to calculate the fluxes of volatile species, such as SiO(g), Si(OH)₄(g), SiO(OH)₂(g), and SiO(OH)(g), produced by the reaction of SiO₂ scale with the combustion air. The resulted weight loss of SiC was then calculated under a variety of combustion environments. The benefit of using environmental barrier coating (EBC) in the protection of SiC from recession was demonstrated by the calculation. It is shown that the weight loss of SiC-based ceramics could be significantly reduced when EBCs, such as mullite (Al₆Si₂O₁₃ or written as 3Al₂O₃·2SiO₂) or SrAS₂ (SrO·Al₂O₃·2SiO₂), are used. The effects of combustion conditions, such as temperature and total pressure, on the volatility of SiO₂ scale were also discussed.     

Assessment of Abrasive Wear of Nanostructured WC-Co and Fe-Based Coatings Applied by HP-HVOF,Flame, and Wire Arc Spray

Thermal spray processes have been widely used to minimize losses caused by wear mechanisms. Sprayed deposits using conventional wire and powder materials have been long solving tribological problems in engineering equipment. More recently, the option for new different technologies and consumables like nanostructured powder materials and nanocomposite cored wires have expanded the possibilities for technical solutions. Cored wire technology allows the use of compositions that cannot be drawn into wire form like carbides in metallic matrix and high-temperature materials, thus, intensifying the use of spraying processes with low operating cost to demanding wear and corrosion applications. The objective of this work was to study the mechanical characteristics and wear performance of coatings obtained by Flame, Wire Arc, and HVOF spraying using selected nanostructured WC10Co4Cr, WC12Co, and Fe-based 140 MXC powder and wire materials. Abrasive wear performance of the coatings was determinate following the ASTM G-65 standard. Based on the results, a higher abrasive wear resistance was found for the HVOF-sprayed WC10Co4Cr nanostructured coating.     

Overview of SIMS-Based Experimental Studies of Tracer Diffusion in Solids and Application to Mg Self-Diffusion

Tracer diffusivities provide the most fundamental information on diffusion in materials, and are the foundation of robust diffusion databases that enable the use of the Onsager phenomenological formalism with no major assumptions. Compared to traditional radiotracer techniques that utilize radioactive isotopes, the secondary ion mass spectrometry (SIMS)-based thin-film technique for tracer diffusion is based on the use of enriched stable isotopes that can be accurately profiled using SIMS. An overview of the thin-film method for tracer diffusion studies using stable isotopes is provided. Experimental procedures and techniques for the measurement of tracer diffusion coefficients are presented for pure magnesium, which presents some unique challenges due to the ease of oxidation. The development of a modified Shewmon-Rhines diffusion capsule for annealing Mg and an ultra-high vacuum system for sputter deposition of Mg isotopes are discussed. Optimized conditions for accurate SIMS depth profiling in polycrystalline Mg are provided. An automated procedure for correction of heat-up and cool-down times during tracer diffusion annealing is discussed. The non-linear fitting of a SIMS depth profile data using the thin-film Gaussian solution to obtain the tracer diffusivity along with the background tracer concentration and tracer film thickness is demonstrated. An Arrhenius fit of the Mg self-diffusion data obtained using the low-temperature SIMS measurements from this study and the high-temperature radiotracer measurements of Shewmon and Rhines (Trans. AIME 250:1021-1025, 1954) was found to be a good representation of both types of diffusion data over a broad range of temperatures between 250 and 627 °C (523 and 900 K).     

Corrosion Resistance Enhancement of AZ91D Magnesium Alloy by Electroless Ni-Co-P Coating and Ni-Co-P-SiO2 Nanocomposite

Electroless Ni-Co-P coating and Ni-Co-P-SiO₂ nanocomposites were successfully applied on AZ91D magnesium alloy via environmentally friendly cerium-lanthanum-permanganate treatment and their properties were compared with traditionally binary Ni-P coating. The prepared coatings were analyzed using scanning electron microscopy, x-ray diffraction, and energy dispersive x-ray spectroscopy. Moreover, the corrosion behavior of the coatings in 3.5 wt.% NaCl was evaluated by two electrochemical methods. It is found that the Ni-Co-P coating possesses more uniform and compact structure and better corrosion protection characteristics in comparison with the Ni-P coating. The plating rate of Ni-Co-P bath is relatively lower than the Ni-P bath, but it significantly increases after addition of SiO₂ nanoparticles more probably due to adsorption of silica nanoparticles on alloy surface. The corrosion resistance of Ni-Co-P-SiO₂ composite coatings was superior with respect to Ni-P and Ni-Co-P coatings due to formation of thick and compact coating with tortuous grain boundaries.     

Laboratory Produced P/M Aluminum 2XXX + Zr Sheet

Laboratory procedures were established to produce advanced aluminum 2XXX+ Zr alloy powder metallurgy sheet in the T8X temper. The sheet was tested for tensile and Kahn Tear properties in the longitudinal and long transverse directions. The results from the laboratory-produced sheet were compared to the results of a pilot-scale NASA contractual study which used the same alloy powders, leading to the conclusion that laboratory-scale sheet properties are good to excellent predictors of the pilot-scale tensile properties and tear notch toughness values. Tear resistance toughness at pilot scale was not satisfactorily predicted by the laboratory results.     

Macrosegregation in ESR and VAR Processes

The method of heat generation, heat transfer characteristics, and ingot structure are very different in the VAR and ESR processes, which result in different tendencies and mechanisms for macrosegregation formation in forged IN-718. Freckles are niobium rich and can be generated in both ESR and VAR, with higher incidence in ESR than VAR. White spots are niobium lean and can only be found in VAR-processed materials. Freckles are indige-nous in nature, and result from the flow of solute-rich interdendritic liquid in the mushy zone during solidification. The most plausible cause for white spots is exogenous material, which remains unmelted, falling into the molten pool. The best way to minimize the formation of freckles is to improve the ingot heat transfer rate, a more difficult task in ESR than in VAR.     

Influence of Electropolishing and Magnetoelectropolishing on Corrosion and Biocompatibility of Titanium Implants

Titanium alloys are playing a vital role in the field of biomaterials due to their excellent corrosion resistance and biocompatibility. These alloys enhance the quality and longevity of human life by replacing or treating various parts of the body. However, as these materials are in constant contact with the aggressive body fluids, corrosion of these alloys leads to metal ions release. These ions leach to the adjacent tissues and result in adverse biological reactions and mechanical failure of implant. Surface modifications are used to improve corrosion resistance and biological activity without changing their bulk properties. In this investigation, electropolishing and magnetoelectropolishing were carried out on commercially pure titanium, Ti6Al4V, and Ti6Al4V-ELI. These surface modifications are known to effect surface charge, chemistry, morphology; wettability, corrosion resistance, and biocompatibility of these materials. In vitro cyclic potentiodynamic polarization tests were conducted in phosphate buffer saline in compliance with ASTM standard F-2129-12. The surface morphology, roughness, and wettability of these alloys were studied using scanning electron microscope, atomic force microscope, and contact angle meter, respectively. Moreover, biocompatibility of titanium alloys was assessed by growing MC3T3 pre-osteoblast cells on them.     

A modular modeling approach for describing the in-plane forming behavior of unidirectional non-crimp-fabrics

Various commercially available unidirectional (UD) non-crimp-fabrics (NCFs) are currently used for manufacturing carbon fiber reinforced plastic (CFRP) parts. These UD NCFs can differ significantly in their forming behavior. For optimizing and ensuring the manufacturability of the forming process of CFRP parts manufactured from UD NCFs these differences have to be taken into account. This motivates developing an efficient and universally applicable modular modeling approach for describing the in-plane forming behavior of various UD NCFs. The first component of this modular approach is a hyperelastic material model that accurately predicts the fiber orientation of UD NCFs during forming. This material model is implemented via a user-defined material subroutine in the commercial finite element package LS-DYNA. The second component is a simple truss structure that allows modeling the various stitch patterns of the different UD NCFs. This modular model can be calibrated via simple tensile tests. To demonstrate the versatility of this approach, the in-plane forming behavior of three different UD NCFs is validated by comparing experimental data and simulation results of the common picture frame test.     

Processing and designing parts using structural reaction injection molding

A new process called structural reaction injection molding (SRIM) has been developed to combine the high strength and modulus properties of fiber reinforced composites with the advantages of the reaction injection molding process. Along with the process, a new reactive resin has been developed expressly for the structural RIM process. With the new resin and SRIM process conventional design methods can be used, but the designer must also consider several facets of the structural RIM process.     

Synthesis and characterization of iron oxide nanoparticles by solvothermal method

In the present work iron oxide nanoparticles have been synthesized by alkaline solvo thermal method using anhydrous ferric chloride, sodium hydroxide, polyethylene glycol and cetyl trimethyl ammonium bromide and characterized by X-ray diffraction (XRD), Fourier Transform Infrared Spectroscopy (FTIR), Field Emission Scanning Electron Microscopy (FESEM), Energy-dispersive X-ray Spectroscopy (EDX) and Thermal Gravimetric Analysis (TGA). XRD indicated that the product is a mixture of different phases of iron oxide viz. gamma-Fe₂O₃ (maghemite, tetragonal), Fe₂O₃ (maghemite, cubic), Fe₃O₄ (magnetite, cubic) and ?-Fe₂O₃(epsilon iron oxide). FESEM studies indicated that size of the particles is observed in the range of about 19.8 nm to 48 nm. EDX spectral analysis reveals the presence of carbon, oxygen, iron in the synthesized nanoparticles. The FTIR spectra indicated absorption bands due to O-H stretching, C-O bending, N-H stretching and bending, C-H stretching and Fe-O stretching vibrations. TGA curve represented weight loss of around 3.0446 % in the sample at temperature of about 180°C due to the elimination of the water molecules absorbed by the nanoparticles from the atmosphere.     

The Center for Microanalysis of Materials

“Excuse me,” said a graduate student that I’ve not seen before, “I’d like to get some time on the Auger.” “Fine” I reply, “If you are going to need a lot of time, Nancy will train you so that you can use the machine yourself. If it’s only a small project, she’ll work with you. In either case, see Nancy to get a session scheduled.” Shaking off the last remnants of sleep, I realize that I’ve forgotten the most important question, “Oh, just a minute …. Why? … I mean, what do you want to find out?” And so begins a discussion which leads to the recommendation that, instead of Auger spectroscopy, the student use a combination of SIMS and STEM. We schedule time appropriately.     

Structural Characterization and Corrosion Stability of a Si-Doped DLC Coating Applied on Cylinder Liner

The aim of this work was to characterize the structure and electrochemical behavior of a silicon-doped diamond-like carbon (DLC) film deposited by hollow cathode plasma immersion ion process (HCPIIP) on a cylinder liner for heavy duty diesel engine. The film structure was characterized by scanning electron microscopy, x-ray diffraction, and Raman spectroscopy. Nanoindentation tests were performed to evaluate the film hardness and Young’s modulus. Monitoring of the open circuit potential with time, electrochemical impedance spectroscopy (EIS), and potentiodynamic polarization measurements was performed in a solution consisting of 0.25 wt.% NaCl + 5.0 wt.% H₂SO₄ at room temperature. The results showed that the film has an amorphous nature consisting of a mixture of sp³ and sp²-like carbon bonds with an I _D/I _G ratio of 0.87. Nanoindentation tests showed that the H/E ratio of the DLC film was 0.102. EIS measurements indicated that the impedance values were higher for the DLC-coated material. Potentiodynamic polarization curves revealed that the corrosion current density was almost three times lower for the coated alloy. The HCPIIP process was considered successful to enhance the surface properties of the cylinder liner.     

Fibers for Structurally Reliable Metal and Ceramic Composites

NASA Lewis Research Center is presently involved in developing structurally reliable metal and ceramic matrix composites for application in advanced gas turbine engines. This paper examines the general property requirements for the high performance fibers of these composites. Also presented are examples of how these fiber property guidelines are influencing current fiber improvement and evaluation studies, with specific emphasis on commercially available boron and SiC fibers.     

Polyolefin Nanocomposites with Enhanced Photostability Weathering Effect on Morphology and Mechanical Properties

This research aims to study the effect of accelerated weathering conditions on the photodegradation characteristics for fibrillar silicate clay-filled Polypropylene (PP) nanocomposites in the presence of metallocene linear low density polyethylene (m-LLDPE). Silane-treated attapulgite (ATP) clay along with ethylene octene elastomer-grafted maleic anhydride (POE-g-MAH) was used to compatibilize both blend and nanocomposite system. The result showed that developed PP/m-LLDPE nanocomposites displayed good UV resistance with little change in retained stress-at-break and elongation-at-break values. Balanced loss of toughness values noted maintaining higher fracture toughness values for nanocomposites containing 5 phr ATP clay. Infrared analysis was used to detect progress of degradation followed by change in carbonyl index revealed predominated chain scission in late irradiation, while crosslinking was dominant for initial irradiation period. An increase in crystallinity during UV exposure (chemi-crystallization) was detected with exposure time for all compositions and virtually independent of initial structure of the polymer. The highest value of crystallization observed for PP and the lowest one for nanocomposites containing 5 phr of ATP clay revealed good oxidation stability. Surface morphology revealed induced degradation throughout cross-section of PP, while severity of the surface degradation was significantly reduced for developed nanocomposites.     

Study of the effect of ion-stimulated deposition assisted by a pulsed laser on the properties of zinc oxide nanocrystalline films

Nanocrystalline thin films of ZnO have been fabricated using the pulsed laser deposition method. The influence of the ion/atom ratio on the structural, morphological, and electrical parameters of these films is considered. It is established that, in the case of ion action on thin films, their crystalline structure and electrophysical properties are significantly changed. It is demonstrated that modes of ion-assisted deposition can help to control the average grain size in the range from 75.4 ± 2.0 nm to 79.1 ± 2.0 nm, the roughness in the range from 2.14 ± 1.11 nm to 7.30 ± 1.25 nm, and the resistivity and mobility in the range from (22.6 ± 2) × 10^?4 Ohm cm to (33.6 ± 2) × 10^?4 Ohm cm and from 28.21 ± 4.60 cm²/V s to 71.92 ± 2.50 cm²/V s, respectively.     

Spectroscopic and microscopic evaluation of immobilized cytochrome c interaction with cyanide/arsenic ligands in quantitative analysis

The electrochemical, spectroscopic and microscopic analyses of cytochrome c and its immobilization on bare glassy carbon (GC) and platinum (Pt) electrodes were performed. Cytochrome c interaction was examined by studying cyanide and arsenic as model compounds for these types of behavior. Subtractively normalized interfacial Fourier transform infrared (SNIFTIR) spectroscopy, fluorescence and electrochemical methods, Fourier transform infrared (FTIR) spectroscopy and atomic force microscopy (AFM) were used to characterize the protein in the immobilized state and to confirm that the protein was not denatured upon binding to the pre-treated bare GC and Pt electrodes. The spherical morphology of the immobilized protein, which is typical of native cytochrome c, was observed using AFM. The protein binding was monitored as a decrease in peak currents (by CV) for the immobilized protein. Under analysis was also a decrease in emission intensities by fluorescence in solution, by the FTIR and SNIFTIR spectroscopies. Fluorescence and AFM proved the existence of the binding process between the protein and the analytes. This behavior was confirmed by the FTIR and SNIFTIR spectroscopies, which gave evidence that the binding event took place at the amino acids side chain of the protein.     

Tantalum—processing,properties and applications

Tantalum— the Earth’s 49th most abundant element— is frequently produced as a by-product of tin smelting. The metal is also extracted from concentrates by reduction with sodium or fused-salt electrolysis; tantalum carbide is produced by carburization of Ta₂O₅ or tantalum hydride. Sintering, electric-arc melting and electron-beam melting are used to refine and purify raw tantalum. Tantalum’s unique properties make it suitable for a number of diverse applications, including capacitors, chemical equipment, hard-metal tooling and alloys. Tantalum consumption is expected to increase in the capacitor market, because of the demand for electronics equipment.     

Rare Earth Additions in Continuously Cast Steel

Rare earth (lanthanide metals) addiiions to continuously cast steel are particularly advantageous because of their ability to refine as-cast structures, reduce segregation and increase hot ductility at temperatures just below that of solidification. The complete shape control of sulfides in steels containing Rare Earth Metals (REM), whether continuously cast or ingot cast, is primarily responsible for improvements in ductility related mechanical properties, weldability, fatigue resistance and resistance to hydrogen damage. Complete sulfide shape control can be obtained with REM additions at sulfur levels as high as.020%. The greatest improvements, however, are obtained with REM additions to low sulfur steels. However, to achieve full operational advantages afforded by REM, nozzle blockage problems must be circumvented. Water model studies indicate a possible solution.