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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Development and Evaluation of Embrittlement Resistant Alloys for Advanced LWR Cladding

The primary challenge preventing the deployment of reactor designs that leverage wrought FeCrAl as an advanced light-water reactor (LWR) cladding is irradiation hardening and embrittlement. Wrought FeCrAl alloys experience a loss of post-irradiation ductility and fracture toughness under low-temperature neutron irradiation (< 350°C) resulting from the combined effects of dislocation loop formation and the irradiation-enhanced precipitation of Cr-rich alpha-prime precipitates throughout the microstructure. Over the past decade, significant improvements in our understanding regarding the effect of Cr and Al content have been enabled through neutron irradiations, but even optimized wrought alloys such as C26M remain vulnerable to brittle failure during storage, transportation, and handling following irradiation. This report summarizes multiple irradiation campaigns initiated over the past 7 years and provides recent insights into the effect of (1) minor alloying composition, (2) alloy processing strategy, (3) crystal structure, and (4) the use of advanced oxide dispersion strengthened (ODS) alloys. The first irradiation campaign irradiated body-centered cubic FeCrAl alloy C26M with and without elements such as Mo and Y. It also included face-centered cubic alumina-forming austenitic (AFA) alloys that have a steeper neutronic penalty but that have far superior high-temperature strength than wrought FeCrAl. Finally, this campaign compared conventional wrought C26M with the same material produced using modern powder metallurgical hotisostatic pressing (PM-HIP). The second irradiation campaign, initiated in 2018, irradiated wrought and FeCrAl-ODS materials up to 50 dpa to assess their irradiation resistance to high-doses. The results of this work indicate that wrought C26M suffers significant degradation following neutron irradiation at LWR-relevant temperatures regardless of Mo and Y content. The PM-HIP variant appears to be more resilient to irradiation-induced ductility loss in comparison with wrought variants but still loses almost all ductility by 8 dpa. Notably, the AFAs retained at least 5% total elongation after irradiation at the same dose and temperature condition, although additional deterioration may be expected at higher fluence levels. FeCrAl-ODS materials show the greatest promise as a transformative longer-term accident-tolerant fuel (LT-ATF) cladding material. The extruded 106ZY10C alloy retained 10% total elongation after 16 dpa irradiation and retained 8% total elongation after 50 dpa. Additional challenges with FeCrAl-ODS alloys also remain, including optimization of end cap joining methodologies, enhancement of fracture toughness, scaling production to prove economic viability, and optimizing post-pilger heat treatments to maximize ductility and irradiation resistance. This series of irradiations demonstrates the efficacy of the LWR testbed available within the United States for the rapid irradiation and down-selection of LT-ATF candidates. As the country rapidly accelerates its timeline for the deployment of advanced reactor concepts, the effective utilization of the High Flux Isotope Reactor for separate-effects style irradiations should continue to be prioritized to answer the final questions pertaining to LT-ATF candidates necessary for the deployment of advanced boiling water reactors and small modular reactors.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Revealing High-Temperature Reduction Dynamics of High-Entropy Alloy Nanoparticles via In Situ Transmission Electron Microscopy

Understanding the behavior of high-entropy alloy (HEA) materials under hydrogen (H 2 ) environment is of utmost importance for their promising applications in structural materials, catalysis, and energy-related reactions. Herein, the reduction behavior of oxidized FeCoNiCuPt HEA nanoparticles (NPs) in atmospheric pressure H-2 environment was investigated by in situ gas-cell transmission electron microscopy (TEM). The reduction reaction front was maintained at the external surface of the oxide. During reduction, the oxide layer expanded and transformed into porous structures where oxidized Cu was fully reduced to Cu NPs while Fe, Co, and Ni remained in the oxidized form. In situ chemical analysis showed that the expansion of the oxide layer resulted from the outward diffusion flux of all transition metals (Fe, Co, Ni, Cu). Revealing the H-2 reduction behavior of HEA NPs facilitates the development of advanced multicomponent alloys for applications targeting H 2 formation and storage, catalytic hydrogenation, and corrosion removal.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2021

Local chemical fluctuation mediated ultra-sluggish martensitic transformation in high-entropy intermetallics

Superelasticity associated with martensitic transformation has found a broad range of engineering applications, such as in low-temperature devices in the aerospace industry. Nevertheless, the narrow working temperature range and strong temperature sensitivity of the first-order phase transformation significantly hinder the usage of smart metallic components in many critical areas. Here, we scrutinized the phase transformation behavior and mechanical properties of multicomponent B2-structured intermetallic compounds. Strikingly, the (TiZrHfCuNi) 83.3 Co 16.7 high-entropy intermetallics (HEIs) show superelasticity with high critical stress over 500 MPa, high fracture strength of over 2700 MPa, and small temperature sensitivity in a wide range of temperatures over 220 K. The complex sublattice occupation in these HEIs facilitates formation of nano-scaled local chemical fluctuation and then elastic confinement, which leads to an ultra-sluggish martensitic transformation. The thermal activation of the martensitic transformation was fully suppressed while the stress activation is severely retarded with an enhanced threshold stress over a wide temperature range. Moreover, the high configurational entropy also results in a small entropy change during phase transformation, consequently giving rise to the low temperature sensitivity of the superelasticity stress. Furthermore, our findings may provide a new paradigm for the development of advanced superelastic alloys, and shed new insights into understanding of martensitic transformation in general.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Uniaxial tensile mechanical properties from a scratch on ultra-fine grained tungsten

We demonstrate that surface-based mechanical testing can be used to quantify a wide range of mechanical properties determined using traditional uniaxial tension experiments. These include mapping of dynamic stress–strain behaviour, which can be used as a screening tool for uniaxial tensile ductility (uniform elongation), fracture toughness (K C ), which is shown to be in good agreement with reported plane-strain K IC , as well work-hardening exponents (n), activation volumes (V) energies (Q) and strain-rate sensitivity (m) exponents as a function of temperature. Advantages of the surface-based approach are the ability to work with significantly smaller volumes and accommodate processing defects like pores, voids and cracks. These methods are applied to ultra-fine grained tungsten (average grain size of 650 nm), as it is an ideal candidate for alloy development efforts in advanced energy systems. Tungsten is a useful baseline as it exhibits a near-ambient temperature (approx. 200°C) ductile-to-brittle transition temperature (DBTT), enabling validation efforts for the proposed methods, and extraordinary material properties, including the highest melting temperature of any metal and complex temperature and strain-rate dependencies linked to transitions in dislocation mechanisms.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Effects of carbonitrides and carbides on microstructure and properties of castable nanostructured alloys

In this work, to develop advanced reduced-activation ferritic-martensitic (RAFM) steels for fusion reactor structural applications, both carbonitride- and carbide-strengthened castable nanostructured alloys (CNAs) were explored for higher densities of MX (M = Ti/Ta/V/etc. and X = C/N) nanoprecipitates. Additionally, systematic comparisons between the two types of CNAs indicated generally similar microstructures and comparable tensile properties and creep resistance. However, the carbide-CNAs did show some advantages over the carbonitride-CNAs in terms of the uniformly distributed higher density of MC nanoprecipitates, greater Charpy impact upper shelf energies, less deuterium retention and swelling, and potentially less transmutation-induced composition changes and consequently thermodynamically more stable carbides. The carbide-CNAs showed the best-balanced high performance in the examined properties, in contrast to the significantly varied performance of oxide-dispersion-strengthened alloys and the generally lower performance of current RAFM steels.

36 MATERIALS SCIENCE↗
DOE OSTI2020

The correlation between microstructure and nanoindentation property of neutron-irradiated austenitic alloy D9

The microstructure and nanomechanical properties of three samples of the modified stainless steel (referred as the alloy D9) were systematically characterized after neutron irradiation in the Advanced Test Reactor. The samples were irradiated to 5.0, 8.2, and 9.2 displacements per atom at 448, 430, and 683°C, respectively. The evolutions of dislocation loops, cavities, and radiation-induced precipitates were quantitatively studied to reveal their dose and temperature dependencies. Nanohardness and nanoindentation creep tests were conducted at room temperature on the irradiated samples. Unexpected radiation hardening was observed in the highest-temperature-irradiated sample due to the formation of an unknown type of Ni- and Si-rich precipitates whose contributions to the radiation and mechanical performances of the alloy were discussed. We provide the radiation-microstructure-property correlations of alloy D9 with new insights, which can benefit the development and optimization of advanced austenitic alloys for future nuclear applications.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Downselection and Basic Properties of Additively Manufactured ODS Alloys

In the AMMT program the work package for development of new materials aimed to explore the advanced manufacturing techniques that are feasible for the manufacturing of advanced materials components. A merit-based feasibility study was attempted to identify an accelerated development path for dispersion strengthened (ODS) alloys by creatively combining additive manufacturing (AM) technologies with the recent advances in ODS materials and traditional manufacturing technologies. For the fiscal year, the primary tasks were focused to develop additive manufacturing (AM) and post-build processing route for oxide dispersion strengthened (ODS) ferritic (Fe-Cr alloy or 14YWT) and austenitic (Fe-Cr-Ni alloys or 316L and 316H) alloys and to perform basic microstructural and mechanical characterizations to provide feedbacks to the alloy and processing design. Further, the multi-laboratory effort created collaboratively a decision criteria matrix to evaluate and downselect the new materials processed by advanced manufacturing methods. This report is to describe the ODS alloy processing routes combining AM processes and post-build thermomechanical treatments, mechanical and microstructural characteristics of the newly developed materials, and the application results of the decision criteria matrix for the AM ODS alloys including a downselected material and feasible processing route. Key mechanical test results including tensile strength, tensile ductility, and fracture toughness data and are reported and explained. Higher strength was measured from the ferritic ODS alloys, while higher ductility and fracture toughness were measured from the austenitic ODS alloys. Many of the decision criteria were scored the same for the AM ferritic and austenitic ODS alloys, however, the generally known fact that the austenitic alloys have higher corrosion resistance and significantly better ductility. Although these scores are not significantly different to make them highly discernable, the austenitic ODS alloys were downselected to be the primary materials group in the future research on ODS materials in AMMT program.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Development of Innovative Non-Concentrated Alloy (NCA) Fuel Cladding for Advanced Nuclear Reactors

As the nuclear energy sector advances toward next-generation reactors, the need for high-performance fuel cladding materials has become increasingly urgent. Traditional alloys like zirconium and stainless steel are reaching their performance limits under higher temperatures, more corrosive coolants, and extended irradiation. This report presents the development of a new class of fuel cladding materials based on Non-Concentrated Alloys (NCAs) ? multi-element systems designed to deliver enhanced mechanical strength, corrosion resistance, and radiation tolerance. Through a combination of computational modeling (Computer Coupling of Phase Diagrams and Thermochemistry: CALPHAD), simulation-guided alloy selection, and experimental fabrication via arc melting and spark plasma sintering (SPS), three strategic alloy design paths were explored: (1) FeCrAl-based NCAs, (2) refractory-lean neutron-efficient alloys, and (3) equimolar high-entropy compositions. Microstructural analysis confirmed the formation of stable body-centered cubic BCC_A2 phases, while mechanical testing demonstrated hardness values significantly exceeding those of conventional cladding materials. The results highlight the tunability of NCA systems and their potential for balancing strength and ductility ? a critical consideration for in-reactor performance. Looking forward, future work will focus on thermomechanical optimization, CALPHAD refinement, and benchmarking against industry standards to enable scalable deployment. This work not only advances the science of nuclear materials but also supports broader goals in nuclear safety, performance, and nuclear energy innovation.

36 - MATERIALS SCIENCE↗
DOE OSTI2020

Hydrothermal corrosion of 2nd generation FeCrAl alloys for accident tolerant fuel cladding

As part of an effort to develop advanced fuel cladding for use in light water reactors, several FeCrAl alloys have been developed at Oak Ridge National Laboratory. A second generation of these alloys bearing additional alloying elements over the previously tested model alloys were tested in boiling water reactor (BWR) conditions to determine their resistance to hydrothermal corrosion. Coupons with alloy compositions Fe–10Cr–6Al–2Mo, Fe–13Cr–5Al–2Mo, Fe–13Cr–6Al–2Mo, Fe–13Cr–7Al–2Mo, and Fe–13Cr–5Al–2Mo–1Nb were tested in normal water chemistry (NWC) and hydrogen water chemistry (HWC) for 9 months in continuously refreshing autoclaves. Commercial FeCrAl alloy APMT and Zircaloy-2 were also tested for comparison. Among samples exposed to HWC, Fe–13Cr–7Al–2Mo performed worst with an average mass loss of 1.3 mg/cm2 over 9 months. This mass loss represents an estimated thickness loss of approximately 60 μm over 6 years. Samples exposed to NWC had very small mass losses of less than 0.15 mg/cm2 or mass gains up to 0.05 mg/cm2. Based on the results of this testing, the 2nd generation FeCrAl alloys tested exhibit low wall thickness loss and are suitable in terms of corrosion resistance for use as LWR cladding in BWR-HWC and BWR-NWC under normal operating conditions.

Raiman, Stephen↗
DOE OSTI2022

The Trajectory of Additively Manufactured Titanium Alloys with Superior Mechanical Properties and Engineered Microstructures

Additive manufacturing (AM) plays a crucial role in the manufacturing and development of advanced materials including titanium alloys for engineering applications. During the last two decades, a great deal of effort has been devoted to print titanium parts with desired properties. However, due to presence of non-equilibrium/metastable phases, anisotropic microstructure, and various porosities in the printed titanium alloys, achieving an excellent combination of mechanical properties has been challenging. Here this review paper aims to provide a comprehensive overview of multiple post-process and in-process approaches to achieve enhanced strength-ductility combinations by microstructure engineering. Approaches such as addition of alloying elements/nucleants, multi-step post heat treatment, in-situ heat treatment, forced inter-pass cooling, in situ peening/rolling, hybridizing microstructure, high-intensity acoustic vibration, thermo-hydrogen refinement of microstructure, deliberately introducing lack of fusion defects with subsequent hot isostatic pressing are discussed in detail. Finally, we conclude by highlighting the challenges associated with each method and potential areas of improvement that can pave the way to develop reliable components with enhanced performance.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Mechanical Performance of Additively Manufactured ODS 316L and 316H Stainless Steels

This work package within the Advanced Materials and Manufacturing Technologies (AMMT) program focused on the mechanical and microstructural characterization of oxide dispersion strengthened (ODS) stainless steels produced using advanced manufacturing techniques. The research aimed to identify an accelerated development path for ODS alloys by integrating additive manufacturing (AM) technologies with recent advancements in ODS materials and traditional manufacturing methods. For FY 24, the research specifically targeted exploring an accelerated development path for ODS alloys by combining AM technologies with these advancements. Novel AM and post-build processing routes were developed for ODS austenitic alloys, including Fe-Cr-Ni alloys such as 316L and 316H. Electron microscopy and mechanical characterizations were conducted to evaluate the impact of process variables on microstructure and properties, with the goal of optimizing these properties economically. Traditionally, producing ODS alloys involves multi-day, high-energy mechanical milling of alloy powder with yttria powder, followed by milled-powder consolidation through extrusion or other methods, and additional thermomechanical processing (TMP) for property control. To overcome the challenges associated with this complex and costly approach, we propose exploring alternative, cost-effective processing routes that emphasize AM and traditional TMP methods. The new processing routes for ODS alloys have achieved significantly higher strengths—several times greater than those of wrought stainless steels—while maintaining substantial ductility and fracture toughness. This report outlines the novel and economical AM-based processing routes for ODS austenitic alloys, combined with post-build TMPs, and discusses the mechanical and microstructural characteristics of the developed materials.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Lifetime Energy Savings Via Advanced Manufacturing of Low Density Steels for Transportation Applications

The purpose of this “Low Density Steels for Transportation Applications” project was to develop an alloy composition and processing parameters that would result in a material suitable for use in automotive structural components at a reduced density over the current advanced high strength steel (AHSS) materials used. The project work successfully developed a robust alloy capable of exceeding project mechanical property targets at each stage of development, with an 8% density reduction over benchmark AHSS materials (7.8 g/cm3). The developed alloy has the potential to offer significant vehicle lightweighting and improved fuel economy, without sacrificing the increased passenger safety of more traditional AHSS. Through the three tasks of the project, (1) Alloy design and small-scale laboratory evaluation, (2) Laboratory development of hot rolled material and (3) Laboratory development of a cold rolled material, the laboratory work utilized advanced characterization and analytical methods on novel alloy compositions subjected to both conventional and non-conventional processing operations.

36 MATERIALS SCIENCE↗
DOE OSTI2021

An Accelerated Creep Testing (ACT) Program for Advanced Creep Resistant Alloys for High Temperature Fossil Energy (FE) Applications (Final Report)

The research objective of this study is to develop an accelerated creep testing (ACT) program for advanced creep resistant alloys for high temperature FE applications. This research produced a new ACT for metallic materials based on Time-Temperature-Stress Superposition (TTSSP). In TTSSP, there exists a fundamental relationship between creep resistance, time, temperature, and stress that can be manipulated to reduce test durations. In our study, the stepped isostress method was employed where step increases of load during creep testing accelerated the time-to-rupture. Well-posed constitutive models including sin-hyperbolic and Wilshire-Cano-Stewart where calibrated using the SSM data and employed to predict the conventional creep response of the material. In our best experiments, <100-hour tests on lnconel 718 at 750 deg C produced over a 64x acceleration of data when compared to conventional data from Japan's National Institute of Materials Science. The ACTs enable the rapid screening of candidate materials, where a small test matrix of short duration tests can be employed to determine the creep resistance (minimum-creep-strain-rate, stress-rupture, and creep deformation) of a material across decades.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2025

INL_intern_poster_RashedA

Advanced nuclear reactors often operate at elevated temperatures, novel fuel with different chemical and thermal properties that may interact differently with cladding, new coolants (e.g., molten salt, liquid metal, or sodium) that are chemically aggressive, requires cladding materials with superior oxidation, corrosion, and creep resistance. Developing fuel cladding for advanced reactors is essential, as the cladding plays a critical role in reactor safety, performance, and longevity. In this study, innovative Non-Concentrated Alloys (NCAs) were developed as novel fuel cladding materials for advanced nuclear reactors. Multiple elements were chosen for the alloys. NCAs were manufactured and tested mechanically, showing promise with the arc-melting method, and setting a clear path for the next step of NCAs' development as a fuel cladding for advanced nuclear reactors.

36 - MATERIALS SCIENCE↗
DOE OSTI2024

Irradiation And Post-Irradiation Examination Plan For A709

The Advanced Materials and Manufacturing Technologies program is proposing a neutron irradiation campaign for alloy 709 (A709) plate product developed by the Advanced Reactor Technologies program. This irradiation campaign will support the deployment of A709 (included welded components) by providing data of engineering importance, such as data that can be used for establishing end-of-life design parameters and knockdown factors for irradiated materials properties versus properties for non-irradiated material. It will also advance the scientific understanding of A709 irradiation behaviors and material property evolution, which is vital for deploying A709 components into reactors with different neutron spectra, neutron fluxes, and irradiation temperatures as well as accelerating the deployment of new product forms and weld procedures. This document presents the plan for the neutron irradiation and post-irradiation examination for A709 and the scientific and technical basis for the plan.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Microstructural Engineering and Accelerated Test Method Development to Achieve Low Cost, High Performance Solutions for Hydrogen Storage and Delivery

This project made advancements in developing lower cost steel alloys with novel microstructural design for use in hydrogen refueling infrastructure such as storage, compressors, and dispensing components, and utilizing accelerated test methods to efficiently evaluate variations in alloy and microstructure design. The project specifically sought to design alloys with lower nickel contents to reduce alloy cost, which was accomplished through substituting manganese for nickel along with other alloy additions to control deformation characteristics known to be important for hydrogen embrittlement resistance. Through Mn substitutions for nickel, austenitic and duplex austenite-ferrite steels were successfully developed with lower cost than currently available commercial stainless steel products that are employed for hydrogen refueling infrastructure. The steels were processed to achieve comparable strength and toughness in hydrogen environments as the commercially available steels containing high Ni contents. To evaluate mechanical performance in hydrogen, a testing methodology was employed to compare ubiquitous laboratory testing using electrochemical hydrogen charging in a liquid electrolyte to less accessible high pressure gaseous testing. While the application of these steels is in high pressure gaseous environments, the electrochemical hydrogen charging tests produced comparable results. Additionally, the Los Alamos Neutron Scatting Center enabled characterization of deformation mechanisms of the steel alloys in the presence of hydrogen, which has been associated with steel alloy characteristics associated with hydrogen embrittlement. Finally, a fracture mechanics based test bed model was developed to predict the influence of hydrogen gas pressure and fatigue conditions on fatigue lifetimes of pressure vessel steels. Together, these developments can be employed to enable lower cost hydrogen fueling infrastructure and more reliable prediction of steel alloy components in hydrogen service conditions. In particular, the newly alloys have the potential to replace stainless steels, having demonstrated comparable performance at substantially reduced cost.

08 HYDROGEN↗
DOE OSTI2023

Development of dual phase soft magnetic laminate for advanced electric machines

The development of dual phase soft magnetic laminate for advanced electric machines at General Electric is summarized, including alloy development, properties, manufacturing trials, prototype experience, potential applications, and future material development. Dual phase soft magnetic laminates provide the flexibility to tune magnetic/non-magnetic state at the desired locations, using solution nitriding treatment with protective mask/coating. This enabling material technology benefits electric machine performance by reducing flux leakage in the laminates. It also decouples the electromagnetic and mechanical design, which opens up the design space for advanced electric machines. Magnetic and mechanical properties of dual phase laminates were compared to commercial FeSi and FeCo soft magnetic laminates. Driven by the market needs for high power density and high-speed electric machines, a synchronous reluctance (SynRel) machine without PMs using dual phase soft magnetic laminates was assessed in machine electromagnetic performance as well as rotor stress analysis by finite element simulation. Successful prototype build and testing further retired manufacturing risks and advanced the technology maturity level. Future material development with higher mechanical strength, higher saturation magnetization, higher permeability, and lower loss are highly desired for ground and air transportation electrification.

Rallabandi, Vandana↗
DOE OSTI2025

Manufacturability and performance response of developed Ni-based alloys for reactor environments

Under the Advanced Materials and Manufacturing Technologies program, two Ni-based alloys fabricated by laser powder bed fusion (LPBF) at Oak Ridge National Laboratory and by laser powder directed energy deposition (LP-DED) at Idaho National Laboratory have been evaluated: γ′-strengthened Haynes 282 and solution-strengthened Inconel 625. Printing defects were observed in the LPBF 282 alloy fabricated using a Renishaw AM250 machine, likely due to particle spattering during printing. For both the LPBF and LP-DED 282 alloys, annealing at 1,180°C for 1 h resulted in partial recrystallization and a bimodal grain distribution, and subsequent aging for 4 h at 800°C led to the formation of a high density of nano-size γ′-strengthening precipitates. Creep testing performed at 750°C revealed lower creep life and ductility for the LPBF and LP-DED 282 compared with wrought 282. X-ray computed tomography combined with optical and scanning electron microscopy microstructural characterization revealed crack formation in the LPBF 282 alloy during creep testing, initiated either from printing defects or from creep cavitation at grain boundaries. Creep cavitation and cracking at grain boundaries were also observed for the LP-DED 282 alloy, and optimization of the printing strategies and postheat treatments will be needed to fabricate high-performance 282 components for high-temperature nuclear applications.

36 MATERIALS SCIENCE↗