arXiv subjects

David C. Dunand

Publications and source records attributed to David C. Dunand.

7 recordsLinked to original sources

arXiv2026

Self-foaming, Sintering-resistant Iron-Tungsten Powders Enable High-Cycle Thermochemical Hydrogen Storage

H2-H2O redox cycling of iron powder beds at 650-800 °C offers a compact, safe, economical hydrogen storage method, but sintering-induced capacity loss has stalled its scalability for decades. Here, we show that adding redox-active tungsten to Fe powders solves this problem in static powder beds: Fe-25W (at%) alloyed powder self-foams during redox cycling via W gas-phase transport, increasing porosity and preserving capacity. In a custom automated reactor, a kilogram-scale powder bed reversibly stores 42g H2 and sustains 96+/-3% capacity utilization over 30 redox cycles. Temperature-resolved in-situ X-ray diffraction reveals a chemical-vapor-transport-mediated self-foaming mechanism that redistributes W to refine the microstructure, complemented by a contact-barrier stabilization mechanism during high-temperature holds. Partial-capacity cycling up to 90 cycles further confirms sintering resistance under incomplete redox conditions. These results establish Fe-W powder beds as a robust, scalable, and compact platform for safe, stationary hydrogen storage.

cond-mat.mtrl-sci↗

arXiv2026

Machine Learning-Driven Creep Law Discovery Across Alloy Compositional Space

Hihg-temperature creep characterization of structural alloys traditionally relies on serial uniaxial tests, which are highly inefficient for exploring the large search space of alloy compositions and for material discovery. Here, we introduce a machine-learning-assisted, high-throughput framework for creep law identification based on a dimple array bulge instrument (DABI) configuration, which enables parallel creep testing of 25 dimples, each fabricated from a different alloy, in a single experiment. Full-field surface displacements of dimples undergoing time-dependent creep-induced bulging under inert gas pressure are measured by 3D digital image correlation. We train a recurrent neural network (RNN) as a surrogate model, mapping creep parameters and loading conditions to the time-dependent deformation response of DABI. Coupling this surrogate with a particle swarm optimization scheme enables rapid and global inverse identification with sparsity regularization of creep parameters from experiment displacement-time histories. In addition, we propose a phenomenological creep law with a time-dependent stress exponent that captures the sigmoidal primary creep observed in wrought INCONEL 625 and extracts its temperature dependence from DABI test at multiple temperatures. Furthermore, we employ a general creep law combining several conventional forms together with regularized inversion to identify the creep laws for 47 additional Fe-, Ni-, and Co-rich alloys and to automatically select the dominant functional form for each alloy. This workflow combined with DABI experiment provides a quantitative, high-throughput creep characterization platform that is compatible with data mining, composition-property modeling, and nonlinear structural optimization with creep behavior across a large alloy design space.

cond-mat.mtrl-sci↗

arXiv2024

Effects of Mischmetal Composition and Cooling Rates on the Microstructure and Mechanical Properties of Al-(Ce, La, Nd) Eutectic Alloys

This study investigates the substitution of cerium (Ce) with mischmetal (MM) in cast Al-MM alloys, focusing on microstructure, hardness, tensile and compression properties, creep resistance, and coarsening resistance. Al-MM alloys with various MM compositions (Ce, Ce-50La, Ce-33La, and Ce-27La-19Nd, weight percent) exhibit near-eutectic and hyper-eutectic microstructures for Al-9MM and Al-12MM compositions, respectively, with similar as-cast hardness (~525 MPa). All Al-9MM alloys show tensile yield stress ~55 MPa, ultimate tensile strength ~130 MPa, and fracture strain ~8%.The microstructural and mechanical properties consistency demonstrates the flexibility of MM compositions in Al-MM alloys. Al-9MM exhibits excellent coarsening resistance, with minimal hardness reduction when exposed to 300 and 350 C for up to 11 weeks, and a modest ~15% hardness reduction at 400 C for 8 weeks, outperforming eutectic Al-12.6Si and Al-6.4Ni alloys. Additionally, Al-9MM shows higher creep resistance at 300 C compared to most precipitate-strengthened Al-Sc-Zr and solid-solution-strengthened Al-Mg/Mn alloys, but is outperformed by eutectic-strengthened Al-6.4Ni and Al-10Ce-5Ni alloys.The effect of casting cooling rate is investigated through wedge casting: Al-9Ce transitions from hypo- to hyper-eutectic as cooling rates decrease, while Al-12Ce consistently shows hyper-eutectic microstructures. Al11Ce3 lamellae become finer and more closely spaced with increasing cooling rates. Al-9Ce maintains steady hardness at high to moderate cooling rates but shows reduced hardness at lower rates, whereas Al-12Ce shows no change in hardness.With a 15% reduction in energy consumption and CO2 emissions, Al-Ce alloys where Ce is replaced with MM offer comparable mechanical properties and enhanced environmental benefits, highlighting the potential of MM as a sustainable alternative.

cond-mat.mtrl-sci↗

arXiv2018

The effect of solidification direction with respect to gravity on ice-templated TiO2 micro-structures

Ice-templating produces materials with aligned, elongated pores via directional solidification of particle suspensions, sublimation of the solidified fluid, and sintering of the particle walls. Most ice-templating studies utilize upward solidification techniques, where solid ice is located at the bottom of the solidification mold, the liquid suspension is on top of the ice, and the solidification front advances upward, against gravity. Liquid water reaches its maximum density at 4°C; thus, liquid nearest the cold source is less dense than warmer liquid above. The lower density liquid nearest the cold source is expected to rise due to buoyancy, promoting convective fluid motion during solidification. Here, we investigate the effect of solidification direction with respect to the direction of gravity on ice-templated microstructures to study the role of buoyancy-driven fluid motion during solidification. We hypothesize that, for upward solidification, the convective fluid motion that results from a liquid density gradient occurs near the solidification front. For downward solidification, we expect that this fluid motion occurs farther away from the solidification front. Aqueous suspensions of TiO2 nanoparticles are solidified upward (against gravity, with ice on bottom and water on top), downward (water on bottom, ice on top), and horizontally (perpendicular to gravity). Microstructural investigation of sintered samples shows evidence of buoyancy-driven, convective fluid flow during solidification for samples solidified upwards (against gravity), including tilting of the wall (and pore) orientation with respect to the induced temperature gradient, ice lens defects, and radial macrosegregation. These features are not observed for downward nor horizontal solidification configurations.

physics.app-ph↗

arXiv2017

Freeze Casting: A Review of Processing, Microstructure and Properties via the Open Data Repository, FreezeCasting.net

Freeze-casting produces materials with complex, three-dimensional pore structures which may be tuned during the solidification process. The range of potential applications of freeze-cast materials is vast, and includes: structural materials, biomaterials, filtration membranes, pharmaceuticals, and foodstuffs. Fabrication of materials with application-specific microstructures is possible via freeze casting, however, the templating process is highly complex and the underlying principles are only partially understood. Here, we report the creation of a freeze-casting experimental data repository, which contains data extracted from ~800 different freeze-casting papers (as of August 2017). These data pertain to variables that link processing conditions to microstructural characteristics, and finally, mechanical properties. The aim of this work is to facilitate broad dissemination of relevant data to freeze-casting researchers, promote better informed experimental design, and encourage modeling efforts that relate processing conditions to microstructure formation and material properties. An initial, systematic analysis of these data is provided and key processing-structure-property relationships posited in the freeze-casting literature are discussed and tested against the database. Tools for data visualization and exploration available through the web interface are also provided.

physics.app-ph↗

arXiv2017

Ice-Templated W-Cu Composites with High Anisotropy

Controlling anisotropy in self-assembled structures enables engineering of materials with highly directional response. Here, we harness the anisotropic growth of ice walls in a thermal gradient to assemble an anisotropic refractory metal structure, which is then infiltrated with Cu to make a composite. Using experiments and simulations, we demonstrate on the specific example of tungsten-copper composites the effect of anisotropy on the electrical and mechanical properties. The results are compared to isotropic tungsten-copper composites fabricated by standard powder metallurgical methods. Our results have the potential to fuel the development of more efficient materials, used in electrical power grids and solar-thermal energy conversion systems. The method presented here can be used with a variety of refractory metals and ceramics, which fosters the opportunity to design and functionalize a vast class of new anisotropic load-bearing hybrid metal composites with highly directional properties.

cond-mat.mtrl-sci↗

arXiv2008

Composition Profiles within Al3Li and Al3Sc/Al3Li Nanoscale Precipitates in Aluminum

An Al-11.3Li-0.11Sc (at. %) alloy was double-aged to induce first alpha'-Al3Sc and then delta'-Al3Li precipitates. Atom-probe tomography revealed both single-phase delta'-precipitates and core-shell alpha'/delta'-precipitates (with respective average radii of 16 and 27 nm, and respective volume fractions of 12 and 9%) conferring a high strength to the alloy. Although the delta'-shells contain little Sc (~0.027 at. %), the alpha'-cores have a high Li content, with an average composition of Al0.72(Sc0.17 Li0.11). The Li concentrations within the delta'-phase and the Li interfacial excess at the delta'/alpha'-interface both exhibit wide precipitate-to-precipitate variations.

cond-mat.mtrl-sci↗