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This STTR addresses a new class of materials, the covetics, using experimental (manufacturing and characterization) and modeling approaches. This research project is interdisciplinary as it spans across manufacturing, mechanical/electrical engineering, materials science, and physics. Our innovative approach provides the DOE three key STTR value elements. I. New materials: novel high conductivity/strength nano C infused Alcv and Cucv covetics. II. Lean Manufacturing and its Cost Model for the Continuous Flow Manufacturing processes needed for Alcv and Cucv wire manufacturing. III. Optimum wiring system design for power with connectors, insulation and shielding. The combined targets are performance increases of over 50% withmore » cost reductions of 25% or more over SOA. This STTR team has complementary expertise, experience in covetics, and is motivated to design, develop and produce the Cucv and Alcv materials.« less

The recent invention of a new processing method for metals and alloys involving the addition of carbon has led to several reports demonstrating an enhancement in the mechanical properties of the materials known as covetics. In this work the corrosion behavior and mechanical properties of a 6061 aluminum-carbon covetic are investigated and explained. Covetic samples with carbon added were found to exhibit a corrosion potential 40-70mV higher than samples processed without the addition of carbon. However, the corrosion current density of the covetic with carbon added relative to samples without carbon added was also increased. Surface characterization following the corrosionmore » testing using scanning electron microscopy, energy-dispersive X-ray spectroscopy, and X-ray diffraction revealed significant differences between the covetic with carbon added and the covetic parent material processed without carbon addition. After corrosion, the surface of the covetic with carbon added showed a alloying element rich surface morphology from the parent alloy and exhibited a smaller grain size than the material processed without carbon. Additionally, changes in the mechanical properties of the covetic were observed with both the hardness and the compressive strength of the covetic increasing as a result of carbon addition. Finally, the observed change in corrosion behavior and mechanical properties of the covetic with carbon added, along with the physical characterization, are consistent with the formation of a secondary phase in the alloy induced by carbon addition during the process used to make the covetic.« less

Tmore » he depth-dependent strain partitioning across the interfaces in the growth direction of the NiAl/Cr(Mo) nanocomposite between the Cr and NiAl lamellae was directly measured experimentally and simulated using a finite element method (FEM). Depth-resolved X-ray microdiffraction demonstrated that in the as-grown state both Cr and NiAl lamellae grow along the $\left(111\right)$ direction with the formation of as-grown distinct residual ~0.16% compressive strains for Cr lamellae and ~0.05% tensile strains for NiAl lamellae. hree-dimensional simulations were carried out using an implicit FEM. First simulation was designed to study residual strains in the composite due to cooling resulting in formation of crystals. Strains in the growth direction were computed and compared to those obtained from the microdiffraction experiments. Second simulation was conducted to understand the combined strains resulting from cooling and mechanical indentation of the composite. Numerical results in the growth direction of crystal were compared to experimental results confirming the experimentally observed trends.« less

Tmore » he depth-dependent strain partitioning across the interfaces in the growth direction of the NiAl/Cr(Mo) nanocomposite between the Cr and NiAl lamellae was directly measured experimentally and simulated using a finite element method (FEM). Depth-resolved X-ray microdiffraction demonstrated that in the as-grown state both Cr and NiAl lamellae grow along the $\left(111\right)$direction with the formation of as-grown distinct residual ~0.16% compressive strains for Cr lamellae and ~0.05% tensile strains for NiAl lamellae. hree-dimensional simulations were carried out using an implicit FEM. First simulation was designed to study residual strains in the composite due to cooling resulting in formation of crystals. Strains in the growth direction were computed and compared to those obtained from the microdiffraction experiments. Second simulation was conducted to understand the combined strains resulting from cooling and mechanical indentation of the composite. Numerical results in the growth direction of crystal were compared to experimental results confirming the experimentally observed trends.« less