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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

The effect of secondary phases on microstructure and irradiation damage in an as-built additively manufactured 316 L stainless steel with a hafnium compositional gradient

Additive manufacturing (AM) or rapid prototyping has become a crucial tool for reducing both cost and time while increasing efficiency in qualifying structural materials for reactor use. In this study, directed energy deposition (DED) was used to develop an as-built 316 L stainless steel sample with three regions of increasing Hf-dopant to study the effects of Hf on the irradiation response of the material. Morphological and microstructural changes were analyzed before and after 2 MeV proton irradiation at 360 °C to a damage of 2.5 dpa at ~ 10 µm below the surface. The addition of Hf effectively suppressed radiation-induced damage (dislocation loops, radiation-induced segregation) due to enhanced point defect recombination. The radiation damage seen in the as-built sample was further compared to a thermo-mechanically treated counterpart of the same fabrication and irradiation parameters which was found to behave superiorly. In conclusion, the increased radiation resistance of this material may be attributed to the as-built microstructure, which includes undissolved Hf particles, delta ferrite grains and cellular sub-grain boundaries that can hinder defect motion.

316L Stainless Steel↗
DOE OSTI2023

Strength mechanisms and tunability in Al-Ce-Mg ternary alloys enabled by additive manufacturing

Al-Ce-based alloys are promising candidates for additive manufacturing (AM) due to their hot-cracking resistance and because they do not require heat treatment to obtain precipitation strengthening. Rapid solidification rates enabled by AM methods can lead to enhanced mechanical properties; however, the strengthening mechanisms over large composition ranges were unclear. Here, combinatorial synthesis by directed-energy deposition (DED) and hardness measurements were used to rapidly map the composition-dependent strength of the ternary Al-Ce-Mg system. Tensile testing and microstructure characterization of selected compositions were performed to elucidate the compositional dependence of the strengthening mechanisms. Al 11 Ce 3 precipitates were present in all cases, and the maximum hardness (1.25 GPa) was measured for the Al-8Ce-10Mg composition. A combination of (i) Hall-Petch strengthening, based on the FCC-matrix-phase cell size; (ii) particle strengthening, based on Al 11 Ce 3 volume fraction and size; and (iii) solid-solution strengthening, based on Mg composition of the matrix phase, were used to account for the measured strengths. Vickers hardness is shown to correlate well with ultimate tensile strength in these alloys, highlighting the value of surface-based techniques for rapid screening.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Relationship between manufacturing defects and fatigue properties of additive manufactured austenitic stainless steel

Tensile properties, fatigue crack initiation, fatigue crack growth rate, and fatigue life are evaluated in 304L austenitic stainless steel fabricated by directed energy deposition (DED). Large lack of fusion (LoF) defects (often >1 mm in length) significantly reduce ultimate tensile strength and ductility, as well as accelerate fatigue crack initiation and reduce fatigue life. In comparison, small spherical defects (<100 μm in diameter) have less effect on tensile and fatigue properties. Fatigue crack growth rate is less severely affected by defects than other properties, showing only local acceleration in the proximity of LoF defects. Therefore, shorter fatigue life is attributed to the role of LoF defects on facilitating fatigue crack initiation and to a lesser extent fatigue crack propagation. Additionally, the fatigue life can be normalized for defects by considering their effect on ultimate tensile strength, suggesting that in the limit of low defect population, the fatigue strength of additively manufactured stainless steel is similar to conventional wrought materials.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Towards additive manufacturing of magnetocaloric working materials

The feasibility of three-dimensional printing via the Directed Energy Deposition (DED) technique is demonstrated for the ferromagnetic AlFe 2 B 2 (aka 1-2-2) compound, which shows promise as a working material for room-temperature magnetocaloric devices. Like many intermetallic materials, the 1-2-2 compound is brittle at room temperature; not only is it difficult to synthesize from the melt, it is challenging to form it into useful geometries necessary for effective heat transfer in magnetocaloric devices. Using Laser Engineered Net Shaping (LENS TM ) synthesis from two powder precursors, AlB 2 and Fe, samples of simple (rod) and complex (honeycomb) architectures were successfully synthesized. Furthermore, the phase constitution and distribution, magnetic transition temperature, and saturation magnetization determined for the LENS TM -synthesized rod sample are all similar to those obtained for 1-2-2 materials made by conventional casting. Further, the measured magnetic entropy change, as determined from Maxwell's Relations applied to magnetic data, indicates that the magnetocaloric response of the annealed LENS TM -printed rod samples are comparable to those of the 1-2-2 compounds made by conventional techniques. These results confirm that complex magnetofunctional shapes, which are needed for efficient energy conversion in magnetocaloric devices, can be rapidly fabricated from the AlFe 2 B 2 compound.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Compositionally-driven surface nanostructuring on refractory compositionally complex alloys under low energy helium bombardment

Additive manufacturing enables user-defined control of the compositional complexity, opening new design spaces for complex concentrated alloys (CCAs). Refractory CCAs may offer enhanced performance in the divertor region of a fusion reactor environment where plasma-facing materials will be subject to high temperatures, low energy He and D particles, and 14 MeV neutrons. In this work, specimens with the nominal composition of NbTaMoTi, NbTaMo, NbTaTi, and NbTa were fabricated via directed energy deposition (DED) then bombarded with 40 eV He ions to a fluence of 2x10 26 m −2 at ∼ 1000 K. Post irradiation, the surface morphology and composition were examined with electron microscopy and x-ray photoelectron spectroscopy to offer information on the spatial distribution of surface nano-structuring. Sub-surface He bubbles driving the nano-structuring were examined with electron microscopy techniques. Analysis indicates the local composition directly influences the He bubble and tendril size, while the region with the highest complexity showed the shortest nano-structuring. Molecular Dynamics simulations complement the experimental results, showing comparable helium bubble growth and migration as a function of compositional complexity. This work demonstrates the compositional dependence of surface nanostructure formation of compositionally complex alloys, important for future design of complex plasma facing materials in fusion reactors.

Complex concentrated alloys↗
DOE OSTI2021

Additive manufacturing of cobalt-based alloy on tool steel by directed energy deposition

Cladding hard-surfacing alloys on tool steel is an effective approach to enhance the surface properties of tool steel. In this study, a Co-based alloy was deposited on tool steel by Directed Energy Deposition (DED) following a three-factor three-level design of experiment matrix with varied laser power, scan speed, and powder flow rate. The microstructure of the deposits was characterized using scanning electron microscopy (SEM). The residual stress on the surface of the samples was measured by the X-ray diffraction (XRD) sin2? technique. The parameters that produced promising deposits were used to fabricate samples for tensile test, four-point bending test, Charpy impact test, and hardness measurement. Our result reveals that the processing parameters have a significant role in the residual stress of the coatings. Residual stress reduces with the increase of laser energy density. Cracks were found at samples with energy density below a threshold. Tensile testing of the coating/substrate combined structure reveals fracture at the coatings with an ultimate tensile strength of 633.9 ± 54.7 MPa. The bi-material interface survived the tensile test, indicating a strong interfacial bond. The four-point bending test of coating/substrate laminates shows an ultimate flexure strength of 860.6 ± 36.9 MPa. Cracks initiated from the coatings ignored the interface and penetrated the substrate, suggesting a solid bi-material bond. Charpy impact test shows the absorbed energy of coating/substrate laminates is more than doubled that of the substrate.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Vapor-Phase Fabrication and Condensed-Phase Application of a MOF-Node-Supported Iron Thiolate Photocatalyst for Nitrate Conversion to Ammonium

Herein we describe a method for synthesizing a nitrate reduction catalyst within a metal organic framework (MOF). The MOF NU-1000, a zirconium-based mesoporous material, is exposed by using atomic layer deposition (ALD) to a vaporous iron amidinate coordination complex and subsequently a dodecanethiol ligand to synthesize an iron thiolate cluster grafted on the zirconium oxide nodes. Structural identification of the cluster is conducted through X-ray absorption spectroscopy (XAS) and differential envelope density (DED) analyses. Once submerged in an aqueous solution containing nitrate (30 ppm of N) and irradiated with light, the MOF/iron thiolate cluster assembly can photochemically transform the nitrate to ammonium ions. We suggest that sequential, self-limiting, atomic (metal ion), and molecular (ligand) deposition onto the reactive nodes of chemically and thermally stable MOFs could prove to be a versatile and attractive method for obtaining nature-inspired chemical catalysts.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Elucidating the geometric and electronic structure of a fully sulfided analog of an Anderson polyoxomolybdate cluster

The catalytic activity of transition metal sulfide (TMS) clusters in small molecule activation, redox transformations, and charge transfer has inspired the design of novel TMS-based materials for energy-related catalysis and chemical applications. Polyoxometalates (POMs), known for their structural diversity, can in principle be transformed into TMS clusters; however, fully sulfided analogs are rarely isolated, likely due to the strong tendency of uncapped TMS clusters to agglomerate. Here, we report the geometric and electronic structure of a capping ligand-free fully sulfided analog of heptamolybdate Anderson POM [Mo VI 7 O 24 ] 6− , synthesized through the sulfidation of a nanoconfined POM secured within a porous Zr-metal organic framework (NU-1000). A combined computational and experimental analysis indicates that the sulfided counterpart of the Anderson POM is geometrically and electronically more sophisticated than the parent POM. Comparison of experimental pair distribution function (PDF) data with computational simulations confirms that, unlike the oxygen-only [Mo VI 7 O 24 ] 6− cluster, the [Mo IV 7 (μ 3 -S) 6 (μ 2 -SH) 6 (S 2 ) 6 ] 2− polythiometalate (PTM) exhibits diverse sulfur anions (S 2− , HS − , S 2 2− ). DFT calculations indicate that H 2 S acts as a reducing agent, and together with terminal disulfide (S 2 2− ) ligands in the PTM structure, facilitates the complete reduction of all seven Mo VI centers in the parent POM to Mo IV . These findings are supported by X-ray photoelectron spectroscopy (XPS), which confirms exclusive Mo IV , and elemental analysis, which shows quantitative sulfur incorporation. Difference envelope density (DED) mapping further reveals that the PTM clusters are spatially confined within the MOF pores, preventing agglomeration and preserving molecular integrity.

Rabbani, S. M. Gulam [The Ohio State University, C↗
DOE OSTI2022

Design of an Additively Manufactured Recuperator With 800 °C Inlet Temperature for sCO2 Power Cycle Application

Abstract Recuperators with design temperatures at and above 800 °C can further increase the thermal efficiency of supercritical CO2 power cycles by enabling higher turbine exhaust temperatures. Mar-M247 is a well-suited nickel-based superalloy for high temperature service due to its high creep strength that prevents excessive material thickness being required for pressure containment. Additive manufacturing using a high-speed laser-directed energy deposition (L-DED) process presents a promising solution, with build trials demonstrating the ability to produce nonconventional flow channels for enhanced heat transfer. A design process is presented that includes aerothermal and mechanical evaluation to maximize performance within the constraints of the manufacturing process. A 2-D heat transfer network and pressure drop code allows prediction of flow distribution and its effect on overall thermal performance. Established literature correlations, along with CFD simulation, inform the prediction of heat transfer coefficients and friction factors for the flowpaths and enhancement features in the heat exchanger core. Mechanical evaluation using finite element analysis (FEA) modeling with the intent of the ASME Boiler & Pressure Vessel Code (BPVC) Section VIII, Div. 2 assesses the operational safety of the design. The detailed design features annular finned passages that take advantage of helical flow paths to distribute the flow from separated headers to shared heat transfer surfaces. Performance predictions for the recuperator at a 50 kW scale provide insights into the feasibility of the additively manufactured (AM) process to produce recuperators on a commercial scale that extend existing operating envelopes.

Engineering↗
DOE OSTI2024

Selective Deposition and Fusion of AISI 316L: An Additive Manufacturing Process for Space Environments via Direct Ink Writing and Laser Processing

Unlocking the potential of additive manufacturing (AM) for space exploration hinges on overcoming key challenges, notably the ability to manufacture or repair parts on-site during exploration missions with consideration of quality, feedstock utilization, and challenges involved in microgravity environments. While there are multiple efforts to investigate the use of existing metal AM processes such as powder bed fusion (PBF), directed energy deposition (DED), and filament-based material extrusion, each process comes with a different set of challenges in space environments. Here, in this work, we introduce a new AM method that integrates the benefits of direct ink writing (DIW) to selectively deposit metallic pastes with laser-based processing to locally debind and subsequently melt and fuse metal powder, layer by layer, enabling the manufacturing of AISI 316L samples with densities exceeding 99.0%. The impact of process parameters on single-track dimensions, surface morphology, and porosity was characterized. The efficacy of laser debinding was assessed via secondary-ion mass spectrometry, permitting the carbon content to be estimated at 0.0152%, which is safely below the acceptable limit (0.03 wt%) for AISI 316L.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Fatigue and Fracture Behavior of Additively Manufactured Austenitic Stainless Steel

Additive manufacturing (AM) includes a diverse suite of innovative manufacturing processes for producing near-net shape components, typically from powder or wire feedstock. Reported mechanical properties of AM materials vary significantly depending on the details of the manufacturing process and the characteristics of the processing defects (namely, lack of fusion defects). However, an excellent combination of strength, ductility and fracture resistance can be achieved in AM type 304L and 316L austenitic stainless steels by minimizing processing defects. It is also important to recognize that localized solidification processing during AIVI produces microstructures more analogous to weld microstructures than wrought microstructures. Consequently, the mechanical behavior of AM austenitic stainless steels in harsh environments can diverge from the performance of wrought materials. This report gives an overview of the fracture and fatigue response of type 304L materials from both directed energy deposition (DED) and powder bed fusion (PBF) techniques. In particular, the mechanical performance of these materials is considered for high-pressure hydrogen applications by evaluating fatigue and fracture resistance after thermally precharging of test specimens in high-pressure gaseous hydrogen. The mechanical behaviors are considered with respect to previous reports on hydrogen-assisted fracture of austenitic stainless steel welds and the unique characteristics of the AM microstructures. Fatigue crack growth can be relatively insensitive to processing defects, displaying similar behavior as wrought materials. Fracture resistance of dense AM austenitic stainless steel, on the other hand, is more consistent with weld metal than with compositionally-similar wrought materials. Hydrogen effects in the AM materials are generally more severe than in wrought materials, but comparable to measurements on welded austenitic stainless steels in hydrogen environments. While hydrogenassisted fracture manifests differently in welded and AM austenitic stainless steel, the fracture process appears to have a common origin in the compositional microsegregation intrinsic to solidification processes.

additive manufacturing, austenitic stainless steel↗
DOE OSTI2019

Hybrid Generative Gear Manufacturing (CRADA NFE-17-06744)

Oak Ridge National Laboratory (ORNL) and Indiana Tool & Manufacturing Company, Inc. (ITAMCO) partnered to fabricate hybrid generative gears that are supposed to be 20% lighter than conventional gears without compromising strength and wear resistance. A two-pronged approach was taken to fabricate hybrid gears, the first one leveraged a design modification to deploy a mesh structure to reduce weight whereas the second approach involved fabricating the gears with a Ti64- B 4 C composites for increased wear resistance. In the first approach, the gear material was a proprietary steel alloy, Ferrium C64 ® , and the focus was to demonstrate weight reducing by leveraging additive manufacturing to deposit fine mesh structure. In the second case, the focus was on material development for gears fabricated via directed energy deposition (DED).

36 MATERIALS SCIENCE↗
DOE OSTI2022

Industrial Deployment of Computer Aided Manufacturing Software for Hybrid Advanced Manufacturing

GibbsCAM, 3D Systems’ software product, is a full-featured CAM system that provides powerful CNC programming, capabilities, and solutions, delivering high quality parts without sacrificing ease of use. Oak Ridge National Laboratory (ORNL) collaborated with GibbsCAM to evaluate their toolpath generating software being developed for both blown powder and hybrid CNC/additive manufacturing machinery. The current approach in toolpath solutions for additive manufacturing is to utilize subtractive toolpaths created by existing CAM software and reversing it for additive manufacturing applications. GibbsCAM is working to develop a full solution to mitigate the challenges that arise with this approach and deploy a fully customized solution for producing quality, reliable components for a range of different DED systems. When successful, this will be an automated solution deployed through a future release of GibbsCAM software.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2021

In-situ Nondestructive Evaluation of In-flight Particle Dynamics and Intrinsic Properties for Directed Energy Deposition

The objective of this exploratory project is to determine the feasibility of using laser diffraction, structured light 3D scanning, and x-ray diffraction for in-situ assessment and inspection of metal directed energy deposition (DED) that is applied to repair components such as engine parts in remanufacturing. During this project, we have successfully published or submitted at least one journal article for each subtask that we identified. One of our conference paper and presentation has won “best paper award” from Manufacturing & Design Division in the Institute of Industrial and Systems Engineers (IISE) Annual Conference 2021. Through this seed grant, we successfully validated the concepts and proved the three in-situ monitoring techniques work well to predict some defects generation during direct energy deposition. We submitted follow-up proposals to continue work on this topic.

36 MATERIALS SCIENCE↗
DOE OSTI2023

ASME Code Qualification Plan for LPBF 316 SS

This report describes a plan to qualify laser powder bed fusion (LPBF) 316 stainless steel for use with the American Society of Mechanical Engineers (ASME) Boiler & Pressure Vessel Code Section III, Division 5 rules for metallic components in high temperature nuclear reactors. Accomplishing this goal would make the material and manufacturing process available to vendors for inclusion in the next generation of advanced, high temperature reactors. The general approach adopted here is to treat LPBF 316 as if it was a completely new material and to develop a plan to qualify the material according to the current ASME practices. One key goal of this work is to explore and develop accelerated qualification approaches that might reduce the time required to qualify new materials by reducing the need for long term testing. However, the qualification plan here does not employ any accelerated qualification approaches to provide a limiting, bounding description of the number, duration, and types of testing required to qualify LPBF 316 without such techniques and to describe a comprehensive dataset that could be used to explore and validate accelerated qualification approaches in the future. The report addresses the fundamental challenges to qualifying Advanced Manufacturing (AM) materials for high temperature applications and summarizes the ASME Section III qualification process as well as current efforts to qualify LBPF and DED 316 for low temperature applications. The report then discusses specific issues, both material and logistical, related to qualifying PBF 316 steel. The final chapters of the report describe a complete test plan designed to generate sufficient data to qualify the material as well as a data management plan for how to store and manage the data to eventually provide the test data packaged needed to qualify the material with ASME.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Microstructure Alignment Effects from Engineered Cooling during Additive Manufacturing of Alnico Magnets from Prealloyed Powder

Alnico is a rare-earth free; permanent magnet (PM) which maintains its saturation magnetization while at temperatures up to 550°C but lacks the coercivity and energy product needed for a wide range of demanding applications. With an optimal set of processing and manufacturing techniques, Alnico could replace Dy-free Nd-Fe-B magnets in certain applications if the microstructure is textured in a $\langle$001$\rangle$ direction. Additive manufacturing (AM) of near-net-shape magnets may provide such texture. To investigate the possibility, directed-energy deposition (DED) in conjunction with an actively cooled substrate was used to build samples with a compositionally modified, gas-atomized, Alnico 8 alloy. The resulting samples were solutionized and quenched, followed by magnetic annealing and a heat treatment. Magnetic properties and microstructures are compared to previous work.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Fabrication of a Liner Assembly for the MARVEL Microreactor

A liner assembly for an intermediate heat exchanger within the MARVEL microreactor at Idaho National Laboratory has been fabricated using laser-based additive manufacturing. The liner design includes challenging features such as long thin walls, overhangs, and tight geometric tolerances. Two versions of the liner assembly, one full length and the other shortened, were printed from several materials (316L SS, Inconel 625, and Inconel 718) using four powder-based laser printers (AddUp BeAM Modulo 400 DED, EOS 290M LPBF, GE Concept M2, and GE Concept Xline 2000R LPBF) located at the Manufacturing Demonstration Facility of Oak Ridge National Laboratory. Dimensional accuracy, print time, and powder utilization have been evaluated to help assess the feasibility of these AM approaches to liner fabrication. Based on this assessment, a potentially cost-effective pathway for fabrication has been proposed.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Benchmark Study Matrix for Microreactor Geometries Relevant to Multiple Developers

A benchmark study was developed that include design, development, manufacturing, and performance measurement of agnostic reactor relevant geometries to support industry’s adoption of advanced manufacturing in a variety of structures. A matrix of five microreactor component geometries, specifically based on the recent feasibility study on a Marvel microreactor liner, was developed and the Pacific Northwest National Laboratory team initiated one material/process combination, namely 316H using laser powder directed energy deposition (DED). Although the benchmark starts initially with simplistic cubical and cylindrical forms, it builds up to a mock-up of a non-proprietary design that can demonstrate a variety of features potentially useful for presenting knowledge to specific designers of microreactors and for the matter also for other reactor type designers. The initial cubical and cylindrical forms are initial steps to obtain surface features and dimensional responses to the identified process parameters to be used in the non-proprietary design mockup.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗