Simulations/Experiments Integration for Next Generation Hypersonic Materials: Session II
Sponsored by: TMS Structural Materials Division, TMS: Alloy Phases Committee, TMS: High Temperature Alloys Committee, TMS: Refractory Metals & Materials Committee
Program Organizers: Thomas Voisin, Lawrence Livermore National Laboratory; Jibril Shittu, Lawerence Livermore National Laboratory; Aurelien Perron, Lawrence Livermore National Laboratory; Joseph McKeown, Lawrence Livermore National Laboratory; Raymundo Arroyave, Texas A&M University
Wednesday 2:00 PM
March 22, 2023
Room: Sapphire I
Location: Hilton
Session Chair: Thomas Voisin, Lawrence Livermore National Laboratory; Jibril Shittu, Lawrence Livermore National Laboratory
2:00 PM Invited
Composite Metal/Ceramic Coatings with Exceptional Thermal Shock Resistance: Zachary Cordero1; Isha Gupta1; 1Massachusetts Institute of Technology
Conventional ceramic TBCs and EBCs can delaminate under the extreme thermal transients experienced in hypersonic flight (e.g., on aerosurfaces or in propulsion devices). In this talk I will introduce a new class of ultra-tough metal/ceramic coatings specifically designed to withstand these extreme conditions. I will describe the processing, unique structure, and attractive properties of these coatings, then examine their performance in an exemplary application where thermal shock precludes the use of conventional EBCs.
2:40 PM
Phase Transforming Metal-ceramic Multilayers for Ultrahigh Temperatures: John Carter Stotts1; Michael Large2; Gregory Thompson2; Christopher Weinberger1; 1Colorado State University; 2University of Alabama
Hypersonic environments require materials that have a combination of strength and high melting temperatures. However, these properties usually make materials brittle and fracture prone at low to moderate temperatures where resistance to fracture is needed. In this talk, we introduce metal-ceramic composite that can be fracture resistant at low temperatures but phase transforms to a UHTC at high temperatures. Specifically, we shown how transition metal carbide/transition metal multilayers can be designed to phase transform from a composite to a monolithic ceramic that has UHTC properties and creep resistance. This is accomplished by integrating computational modeling of the phase transformation, theoretical modeling of the fracture resistance, and experimental demonstration of the phase transformation properties. We further demonstrate how these materials can be optimized for the phase transformations and how the can be synthesized from standard processing routes.
3:00 PM Invited
On the Deformation Processes of BCC Refractory Complex Concentrated Alloys: Jean-Philippe Couzinie1; Clémence Tafani1; Frederic Mompiou2; Milan Hezcko3; Veronika Mazanova3; Oleg Senkov4; Rajarshi Banerjee5; Maryam Ghazisaeidi3; Michael Mills3; 1Université Paris Est ICMPE; 2CEMES; 3Ohio State University; 4Air Force Research Laboratory; 5University of North Texas
Refractory high-entropy alloys (RHEAs) and complex concentrated alloys (RCCAs) are among the most studied materials in the metallurgical field. They own microstructures based on BCC structure, mainly, but could also exhibit B2 order when aluminum is added. Even if they are considered as promising structural materials for high temperature applications, some basic challenges have still to be addressed. The understanding of the deformation mechanisms is one of these. Hence, the present talk will first provide an overview on the properties of RHEAs and RCCAs based the analysis of the existing data from the available literature. The emphasis will then be put on recent observed deformation mechanisms bringing new insight of the mobility of dislocations in such complex materials. The influence of the presence of B2 order will also be analyzed in details.
3:40 PM Break
4:00 PM
Material Design by Additive Manufacturing of Multi-component Metal Alloys: Wen Chen1; 1University of Massachusetts-Amherst
The increasing demands for materials require increasingly complex compositions and microstructures, which meanwhile bring grand challenges in processing and understanding of microstructure-property relationships in these materials. In this talk, I will present some recent work in our group on fabrication of compositionally complex metal alloys by additive manufacturing, which enables the access of engineered hierarchical microstructures with excellent mechanical properties. Specifically, I will discuss the potential of using laser additive manufacturing and direct ink writing based 3D printing techniques to fabricate some compositionally complex metal alloys such as metallic glass composites and high-entropy alloys with heterogeneous microstructures by tailoring the additive manufacturing process protocol towards superior mechanical performance.
4:20 PM
Degradation Resistance of Refractory Multi-principal Element Alloys for Extreme Environments: Jibril Shittu1; Connor Rietema1; Michael Juhasz1; Zachary Sims1; Hunter Henderson1; Alexander Baker1; Kate Elder1; Joel Berry1; Aurélien Perron1; Brandon Bocklund1; Thomas Voisin1; Scott Mccall1; Joseph Mckeown1; 1Lawerence Livermore National Laboratory
With a renewed interest in advancing the capability of materials for extreme conditions, tailoring multi-principal element alloys (MPEAs) to achieve ultra-high strength and degradation resistance are of paramount importance. Exploiting the wider compositional landscape of MPEAs allows tailoring fundamental metallurgical properties such as microstructure, phase stability, thermal conductivity, and the coefficient of thermal expansion needed to develop degradation resistant alloys. This presentation introduces candidate MPEAs that were experimentally confirmed to exhibit improved thermal transport properties, strength, tribological resistance, and oxidation resistance at room temperatures and elevated temperatures. Highlights of this study promotes the potential of utilizing MPEAs for harsh environments by characterizing their retained mechanical properties at elevated temperatures, and extended service life when compared to current structural materials.Prepared by LLNL under Contract DE-AC52-07NA27344.
4:40 PM
Accelerating a Digital Twin of Direct Energy Deposition Additive Manufacturing: Saad Khairallah1; 1Lawrence Livermore National Laboratory
A multi-scale high fidelity model is developed to simulate the process of additively manufacturing small coupon parts in direct energy deposition. The model accounts for powder transport from the coaxial nozzle to the work piece as well as the effect of the carrier gas. Full laser ray tracing model is used to preheat the flying powder particles and to create the melt pool. Furthermore, microstructural cellular automata finite element analysis is carried out to determine the grain size distribution and orientation upon solidification. The high cost of modeling is brought down by using deep learning neural network as well as data driven reduced order modeling. The model is preliminarily applied to study several Titanium based alloys and to compare resulting microstructure and mechanical performance. This work was performed under the auspices of the U.S. Department of Energy by Lawrence Livermore National Laboratory under contract DE- AC52-07NA27344. Lawrence Livermore National Security, LLC. LLNLABS-837562.