Mechanical alloying, compaction by cold isostatic pressing, and pressureless sintering were used to study the potential for W â 3 wt% Ni â 1 wt% Fe to be processed into the bulk nanocrystalline form as a replacement material for depleted uranium in kinetic energy penetrators. Milling time and sintering temperature were varied from 15 to 100 hours and 1000 to 1300°C respectively. Particle size analysis and SEM showed a bimodal particle size distribution with most of the particles below 10 µm in size. XRD peak broadening analysis showed crystallite size to be reduced to below 50 nm, while peak shifting indicated a reduction in W lattice parameter due to dissolution of Ni and Fe atoms into the W BCC lattice. Post-sintering bulk characterization showed density increasing strongly with increasing sintering temperature to above 90% of theoretical density at 1200°C. Apparent activation energy for sintering decreased strongly with increasing milling time. SEM micrographs showed a bimodal grain size distribution with some areas of smaller submicron grains and others with larger grains on the order of 1 – 4 µm, likely connected to the bimodal particle size distribution from milling. XRD and SEM also showed the precipitation of two secondary phases during sintering: (Fe, Ni)6W6C incorporating carbon from the grinding media and an FCC solid solution of Ni, Fe, and W. The intermetallic carbide phase will increase strength but reduce ductility of the bulk material, which is not desirable. Micro and macrohardness testing show similar trends as density with a strong correlation with sintering temperature. / Master of Science

A specialty class of alloys known as tungsten heavy alloys (WHAs) possess extremely desirable qualities for adoption in nuclear fusion reactors. Their high temperature stability, improvement in fracture toughness over other brittle candidates, and promising performance in initial experimental trials have demonstrated their utility, and recent advancements have been made in understanding and applying these multiphase materials systems. To that end, Pacific Northwest National Laboratory in collaboration with Virginia Tech have sought to understand and tailor the structure and properties of these materials to optimize them for service in fusion reactor interiors; thereby improving the robustness, efficiency, and longevity of structural materials selected for service in an extremely hostile environment. In this analysis of material viability, a multiscale investigation of the connections between structure-property relationships in these multiphase composite microstructures has been undertaken, employing advanced characterization techniques to bridge the macro, micro, and nanoscales for the purpose of generating a framework for the understanding of the ductile phase toughening effect in these systems. This analysis has yielded evidence suggesting the effectiveness of WHA microstructures in the simultaneous expression of high strength and toughness owes to the intimately bonded nature of the boundary which exists between the dissimilar phases in these bi-phase microstructures. Analytical techniques have been employed to provide added dimensionality to traditional materials characterization techniques, providing the first three-dimensional microstructure reconstructions exhibiting the effects of thermomechanical processing on these dual-phase microstructures, and the first time-resolved approach to the observation of WHA deformation through in-situ uniaxial tension testing. The contributions of purposefully introduced microstructural anisotropy and its contribution to texturing and boundary conformations is discussed, and an emphasis has been placed on the study of the interface between the dissimilar phases and its role in the overall expression of ductile phase toughening. In short, this collective work utilizes multiscale and multidimensional characterization techniques in the in-depth analysis and discussion of WHA systems to connect their structure to the properties which make them excellent candidates for fusion reactor systems. / Doctor of Philosophy / In the ongoing effort to realize nuclear fusion for commercial energy generation, there are numerous hurdles which must be overcome. A primary issue in the creation of these reactors is the implementation of materials which interface with the superheated plasma in the reactor interior, called plasma facing materials and components (PFMCs). These PFMCs must be able to withstand environmental conditions which will melt, irradiate, embrittle, and fracture a majority of common structural materials. Therefore these materials must exhibit unparalleled robustness in the form of high thermal and irradiation resistance. One class of alloys which is currently being considered for this purpose is tungsten heavy alloys (WHAs). These materials have exhibited excellent viability in early-stage experimental trials, and have necessarily become the subject of extended examination as PFMC candidates. In a joint collaboration between Pacific Northwest National Laboratory and Virginia Tech, these materials have been subjected to rigorous experimental testing and analysis to determine what underlying physics are responsible for their excellent properties. Advanced analytical techniques have been applied to observe the connections which exist between the atomic structure of boundaries and have been connected to the expression of observable properties on the macroscale. This work has provided the first available data on the full three-dimensional approach to the study of WHAs as well as the first dynamic observation of how the materials deform, leading to the conclusion that the two-phase composite-like structure of these alloys owe their combination of strength and ductility to the strong bond which exists between the two phases. This information on how material structure influences properties can be used to improve alloy design and produce even more effective WHA materials going forward.

During high strain rate deformations of metals and metallic alloys, narrow regions of intense plastic deformations have been observed experimentally. The phenomenon is termed strain localization and is usually a precursor to catastrophic failure of a structure. Similar phenomenon has been observed in glassy polymers deformed both at slow and high strain rates. Whereas strain localization is attributed to material softening due to thermal heating in metallic alloys, it is believed to be due to the reorganization of the molecular structure in polymers. Here we numerically study the strain localization in Tungsten Heavy Alloys (WHAs), and glassy polymers. WHAs are heterogeneous materials and thus inhomogeneities in deformations occur simultaneously at several places. Thus strains may localize into narrow bands at one or more places depending upon the microstructure of the alloy. We analyze the strain localization phenomenon during explosion and implosion of WHA hollow cylinders. We have developed a procedure to generate three-dimensional microstructures from planar images so that the two have the same 2-point correlation function. The WHA considered here is comprised of W particulates in a Nickel-Iron (NiFe) matrix, and each constituent is modeled as a heat conducting, strain hardening, strain-rate hardening and thermally softening elastic-plastic material. Furthermore, the porosity is taken to evolve in each constituent and the degradation of material properties due to porosity is incorporated into the problem formulation. It is found that the strain localization initiation in WHA hollow cylinders does not significantly depend on microstructural details during either explosive or implosive loading. However, the number of disconnected regions of localized deformations is influenced by the microstructure. We have generalized constitutive equations for high strain rate deformations of two glassy polymers, namely, Polycarbonate (PC) and poly (methyl methacrylate) (PMMA). These have been validated by comparing computed results with test findings in uniaxial compression at different axial strain rates, and subsequently used to study strain localization in a plate with a through-the-thickness elliptic hole at the centroid and pulled axially at a nominal strain rate of 5,000 /s. For the problems studied, the intensely deformed narrow regions have very high shear strains in WHAs, but large axial strains in glassy polymers. / Ph. D.