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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 415 records · Page 23
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Composition-dependent apparent activation-energy and sluggish grain-growth in high entropy alloys

Experimental results reveal that the apparent activation-energy for grain-growth in an fcc-based Al x CoCrFeNi high entropy alloy (HEA) system increases from 179 to 486 kJ/mol when the Al content increases from x = 0.1 to 0.3. These unexpectedly high apparent activation-energy values can be potentially attributed to solute clustering within the fcc solid-solution phase that develops with increasing Al content in this HEA. Detailed microstructural analysis using atom-probe tomography and density functional theory (DFT) calculations strongly indicate the presence of such nanoscale clusters. This phenomenon can change grain-growth from a classical solute-drag regime to a much more sluggish cluster-drag based mechanism in these HEAs.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Tungsten doped diamond shells for record neutron yield inertial confinement fusion experiments at the National Ignition Facility

We report on fabrication and characterization of layered, tungsten doped, spherical about 2 mm diameter microcrystalline diamond ablator shells for inertial confinement fusion (ICF) experiments at the National Ignition Facility. As previously reported, diamond ICF ablator shells can be fabricated by chemical vapor deposition (CVD) on solid spherical silicon mandrels using an ellipsoidal microwave plasma reactor. In the present work, we further developed these ablator shells by embedding a W -doped diamond layer sandwiched between two undoped diamond regions. W incorporation in diamond was achieved by adding tungsten hexacarbonyl to the CH 4 /H 2 CVD feed gas. We observe that the W doping concentration decreases with increasing deposition rate which, in turn, is controlled by adjusting the total gas pressure. Cross sectional microstructural analysis reveals sharp interfaces between doped and undoped regions of the diamond shell and uniform W distribution with concentrations up to about 0.3 at.%. At higher W concentrations (>0.3 at.%) formation of tungsten carbide precipitates is observed. Using a 3-shock 1.6 MJ laser pulse, the targets described in this work produced the first laser driven implosion to break the 1 × 10 16 neutron yield barrier, followed by experiments (described in future publications) with similar targets and slightly more laser energy producing yields as high as 4 × 10 17 .

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2012

Synthesis of BaTiO[subscript 3]-20wt%CoFe[subscript 2]O[subscript 4] Nanocomposites via Spark Plasma Sintering

Barium titanate-20wt% cobalt ferrite (BaTiO{sub 3}-20wt%CoFe{sub 2}O{sub 4}) nanocomposites were sintered from nanocrystalline BaTiO{sub 3} and CoFe{sub 2}O{sub 4} powders using spark plasma sintering (SPS) and pressureless sintering (PS) techniques. Using SPS, dense polycrystalline composites were obtained at a sintering temperature as low as 860 C and a time of 5 min whereas PS required a higher sintering temperature (1150 C) and time (120 min) to obtain similarly dense composites. Microstructural analysis of the composites showed that both the techniques retained nanocrystalline grain sizes after sintering. High resolution X-ray diffraction measurements revealed that the BaTiO{sub 3}-20wt%CoFe{sub 2}O{sub 4} composites sintered by the SPS technique did not exhibit formation of any new phase(s) due to reaction between the BaTiO{sub 3} and CoFe{sub 2}O{sub 4} phases during sintering. However, the PS technique resulted in the formation of additional phases (other than the BaTiO{sub 3} and CoFe{sub 2}O{sub 4} phases) in the composites. While the composites synthesized by SPS were of superior phase-purity, evidence of Fe diffusion from the spinel to the perovskite phase was found from X-ray diffraction and permittivity measurements.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Phase Relationship and Ionic Conductivity in Na–SrSiO 3 Ionic Conductor

The Na–SrSiO 3 as a potential high‐conductivity ionic conductor for intermediate temperature solid oxide electrochemical cells (SOECs) has drawn much attention recently. Some of these studies questioned the feasibility of Na doping and therefore the creation of oxygen vacancies, while others suggested an alternative phase responsible for the ionic conduction. In this study, a systematic investigation was carried out to understand the ionic conduction in Na–SrSiO 3 . Through in situ high‐temperature X‐ray diffraction, thermal analysis, microstructural characterization, and electrical conductivity measurement, Na–SrSiO 3 was shown as a two‐phase material, one being slightly Na‐doped SrSiO 3 and another being amorphous Na 2 Si 2 O 5 . The former was an electrical insulator whereas the latter was a good ionic conductor. It was also found that the amorphous Na 2 Si 2 O 5 phase was unstable at the temperature ≥500°C, crystallizing into the insulating polycrystalline Na 2 Si 2 O 5 which causes conductivity to “bend‐over” at higher temperatures. A preliminary Ab Initio Molecular Dynamics ( AIMD ) simulation suggested that the amorphous Na 2 Si 2 O 5 be predominantly a Na + conductor.

Jee, Youngseok↗
DOE OSTI2015

Influence of Microstructure and Surface Activation of Dual-Phase Membrane Ce 0.8 Gd 0.2 O 2-δ -FeCo 2 O 4 on Oxygen Permeation

In dual-phase oxygen transport membranes we noticed that there is fast-growing interest in research for oxyfuel combustion process application. One such potential candidate is CGO-FCO (60wt% Ce 0.8 Gd 0.2 O 2-δ -40wt% FeCo 2 O4) identified to provide good oxygen permeation flux with substantial stability in harsh atmosphere. Dense CGO-FCO membranes of 1mm thickness were fabricated by sintering dry pellets pressed from powders synthesized by one-pot method (modified Pechini process) at 1200 degrees C for 10h. Microstructure analysis indicates presence of a third orthorhombic perovskite phase in the sintered composite. We also identified that the spinel phase tends to form an oxygen deficient phase at the grain boundary of spinel and CGO phases. Surface exchange limitation of the membranes was overcome by La 0.6 Sr 0.4 Co 0.2 Fe 0.8 O 3-δ (LSCF) porous layer coating over the composite. Moreover, the oxygen permeation flux of the CGO-FCO screen printed with a porous layer of 10mthick LSCF is 0.11mL/cm 2 per minute at 850 degrees C with argon as sweep and air as feed gas at the rates of 50 and 250mL/min.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Age and growth of early‐life‐stage Atlantic tarpon ( Megalops atlanticus) from the northcentral Gulf of Mexico

Abstract Age and growth of early‐life‐stage Atlantic tarpon Megalops atlanticus collected from Mississippi coastal waters in the northcentral Gulf of Mexico (GOM) are described using otolith microstructure analysis. Tarpon leptocephali ( n = 95, 16.0—27.8 mm standard length, L S ) collected from June throughOctober 2013—2018, ranged in age from 22 to 43 days (mean = 30.9 ± 0.5 days). Leptocephalus somatic growth rates ranged 0.46—1.24 mm day −1 (mean = 0.76 ± 0.02 mm day −1 ), and leptocephalus otolith growth rates ranged 1.78—3.97 μm day −1 (mean = 2.58 ± 0.04 μm day −1 ). Growth rates were inversely correlated to leptocephalus age, indicating the shrinkage phase associated with leptocephalus metamorphosis. Juvenile tarpon ( n = 358, 50—359 mm fork length, L F ) were collected from August through December 2007—2018. Juveniles exhibited a positive allometric relationship (adjusted R 2 = 0.99, P < 0.001) between length and mass. The age of 100 juveniles (71—277 mm L F ) ranged from 76 to 174 days. Juvenile growth rate was estimated as 1.56 ± 0.11 mm day −1 . Significant ( P < 0.001) linear relationships were found between juvenile age and otolith metrics, including otolith mass ( R 2 = 0.81) and radius ( R 2 = 0.68). Evaluation of the backcalculated hatch dates suggests that specimens in the collection hatched from late May through mid‐September with slight peaks during July and August. A Rao's Spacing Test of Uniformity indicates the presence of significant lunar periodicity in leptocephalus hatch dates ( n = 95, U = 250.1, P < 0.05), with 50% of the leptocephali hatched within 5 days (before or after) of the full moon. This study fills critical gaps in the scientific knowledge of tarpon and provides estimates of early‐life‐history metrics for an iconic game fish at the northernmost extent of its GOM range.

Graham, Patrick M.↗
DOE OSTI2018

Investigation of Interfacial Layer for Friction Stir Scribe Welded Aluminum to Steel Joints

Friction stir scribe (FSS) welding as a recent derivative of friction stir welding has successfully fabricated a linear joint between automotive Al and steel sheets. However, there is a lack of understanding on its bonding mechanism. In this paper, the microstructures and phases at the bonding interface of FSS welded Al to ultra-high strength steel joints were studied using scanning electron microscopy and transmission electron microscopy. Based on the microstructural analysis, it is found that both mechanical and chemical bonding occurred simultaneously, and the energy-dispersive X-ray spectroscopy revealed that a thin intermetallic compound (IMC) layer was formed at the interface. Owing to the varied material flow and heat generation, the IMC layer thickness gradually decreased from the advancing side to the retreating side, and two IMCs (i.e. Fe2Al5 and Fe4Al13) were confirmed in different weld regions using diffraction pattern (or 1D fast Fourier transform pattern). Also, a Fe/Al solid solution was noticed in the IMC layer, and several Al fringes were found in the Fe-rich side in the scribe stir zone.

friction stir scribe welding, interfacial layer, i↗
DOE OSTI2023

Property-Graded Stainless Steel 316L by Selective Laser Melting: Characterization & Design

Abstract The purpose of this research work is to characterize and inform the design of (mechanical) property-graded bulk structures made from a single metallic alloy via a laser powder bed fusion (LPBF) process, with an end goal of creating repeatable/reproducible functionally-graded additively manufactured (FGAM) parts. This paper specifically investigates the manufacture of stainless steel (SS) 316L structures via a pulsed selective laser melting (SLM) process, and the underlying causes of property variations (within a functionally-acceptable range) through various material characterization techniques. For this, a design of experiments spanning the volumetric energy density (VED) based process parameter design space was utilized to investigate the range of functionally-acceptable physical/mechanical properties achievable in SS 316L. Five sample conditions (made via different process parameter combinations) were down-selected for in-depth microstructure analysis and mechanical/physical property characterization; these were suitably selected to impart a wide and controllable property range (209–318 HV hardness, 90–99.9% relative density, and 154–211 GPa modulus). It was observed that property variations resulted from combinations of porosity types/amounts, martensitic phase fractions, and grain sizes. Based on these findings, property-graded standard test specimens were designed and manufactured for further investigation—tensile specimens having a monotonic hardness change along its gauge length, four-point bending specimens with varying elastic moduli as a function of the distance from the neutral axis, and Moore’s rotating beam fatigue specimens with moduli variations based on the distance from the center. Altogether, this work lays the foundation for understanding and designing the local and global mechanical performance of FGAM bulk structures.

Engineering↗
DOE OSTI2023

Neutron Characterization of 3D Printed Gas Turbine Alloy With Internal Cooling Structure

The objective of this research work is to investigate the residual strains induced by the presence of a exit hole and internal hollow geometry present in a 3D printed IN718 similar to that seen in a gas turbine blade. The specimens were manufactured with an internal hollow structure that ended with an exit hole, and fabricated by direct metal laser sintering additive manufacturing technique. Using this technique, metal powder was melted by a laser source and rapidly cooled to form the part layer by layer. Rapid heating and cooling generate large thermal gradients and residual stresses in the 3D printed material. To be aligned with industry standards, specimens were heat-treated to relieve most of the residual stresses as well as to investigate whether IN718 still preserved a nonhomogeneous stress state after the thermal treatment. Roughness and microstructure analysis was performed to understand the heat-treated sample properties. To investigate the volumetric residual strain, the neutron diffraction technique was used with a definite neutron wavelength. Bragg’s law was used to determine lattice spacing. Interplanar lattice spacing and stress-free state lattice spacings were measured to calculate the strains. Residual strains were measured in the x and y direction to understand the impact of the presence of a exit hole and internal hollow geometry. The results of volumetric residual strain in the x and y directions showed no significant variations in the distribution of the strain due to the presence of a hollow structure as well as the exit hole. Overall, no significant stress concentration was observed in the heat treated sample. Sample geometry, instrumentation for neutron diffraction, and material properties are discussed in detail in this paper.

Raju, Nandhini↗
DOE OSTI2025

Compatibility of molten plutonium with wrought and additively manufactured metal crucibles

Understanding plutonium’s interaction with metals is crucial for optimizing pyrochemical operations, nuclear fuel containment, and various actinide processing techniques. Traditionally, tantalum crucibles are employed for plutonium processing due to their high durability, excellent temperature stability, and low solubility in plutonium. However, tantalum faces challenges such as plutonium wetting and diffusion, making surface coatings particularly important for crucibles in pyrochemical applications to enhance corrosion resistance against plutonium. Tantalum is also expensive and difficult to machine, prompting the need for advanced manufacturing techniques to address these challenges. Here, in this work, we investigate the interaction of Pu with tantalum and titanium crucibles fabricated using both traditional machining methods and laser powder bed fusion (LPBF) additive manufacturing (AM). LPBF-AM is an advanced technique that allows for the creation of complex geometries from traditionally difficult-to-machine metals by using a high-powered laser to build parts. Previous studies of conventional manufactured tantalum have utilized oxidation and carburization of the surface to mitigate plutonium wetting; however, no studies of surface modified LPBF-AM material have been undertaken. These studies are crucial, given the typical differences in the grain structure between conventional and LPBF-AM materials. All crucibles underwent differential scanning calorimetry to confirm the melting of plutonium. Subsequently, the crucibles were sectioned and mounted in epoxy for microstructural analysis using optical microscopy and scanning electron microscopy. This investigation, comparing the performance of wrought vs AM metal crucibles, provides a basis for future tooling applications in actinide processing techniques and can address the challenges associated with traditional machining, particularly in pyrochemical applications.

Actinides↗
DOE OSTI2018

Advanced Synthesis of Na 4 Si 24

The recently discovered orthorhombic allotrope of silicon, Si 24 , is an exciting prospective material for the future of solar energy due to a quasi-direct bandgap near 1.3 eV, coupled with the abundance and environmental stability of silicon. Synthesized via precursor Na 4 Si 24 at high temperature and pressure (~850 °C, 9 GPa), typical synthesis results have yielded polycrystalline samples with crystallites on the order of 20 μm. Several approaches to increase the crystal size have yielded success, including in-situ thermal spikes and refined selection of the starting materials. Microstructural analysis suggests that coherency exists between diamond silicon (d-Si) and Na 4 Si 24 . This hypothesis has led to the successful attempts at single crystal synthesis by selecting large crystals of d-Si along with metallic Na as the precursors rather than powdered and mixed precursor material. The new synthesis approach has yielded single crystals of Na 4 Si 24 greater than 100 μm. These results represent a breakthrough in synthesis that enables further characterization and utility. The promise of Si 24 for the future of solar energy generation and efficient electronics is strengthened through these advances in synthesis.

catalysis (heterogeneous)↗
DOE OSTI2016

Fatigue stress concentration and notch sensitivity in nanocrystalline metals

Recent studies have shown the potential for nanocrystalline metals to possess excellent fatigue resistance compared to their coarse-grained counterparts. Although the mechanical properties of nanocrystalline metals are believed to be particularly susceptible to material defects, a systematic study of the effects of geometric discontinuities on their fatigue performance has not yet been performed. In the present work, nanocrystalline Ni–40 wt%Fe containing both intrinsic and extrinsic defects were tested in tension–tension fatigue. The defects were found to dramatically reduce the fatigue resistance, which was attributed to the relatively high notch sensitivity in the nanocrystalline material. Microstructural analysis within the crack-initiation zones underneath the defects revealed cyclically-induced abnormal grain growth (AGG) as a predominant deformation and crack initiation mechanism during high-cycle fatigue. Furthermore, the onset of AGG and the ensuing fracture is likely accelerated by the stress concentrations, resulting in the reduced fatigue resistance compared to the relatively defect-free counterparts.

36 MATERIALS SCIENCE↗
DOE OSTI2012

Ceramographic Examinations of Irradiated AGR-1 Fuel Compacts

The AGR 1 experiment involved irradiating 72 cylindrical fuel compacts containing tri-structural isotropic (TRISO)-coated particles to a peak burnup of 19.5% fissions per initial metal atom with no in-pile failures observed out of almost 300,000 particles. Five irradiated AGR 1 fuel compacts were selected for microscopy that span a range of irradiation conditions (temperature, burnup, and fast fluence). These five compacts also included all four TRISO coating variations irradiated in the AGR experiment. The five compacts were cross-sectioned both transversely and longitudinally, mounted, ground, and polished after development of careful techniques for preserving particle structures against preparation damage. Approximately 40 to 80 particles within each cross section were exposed near enough to mid-plane for optical microscopy of kernel, buffer, and coating behavior. The microstructural analysis focused on kernel swelling and porosity, buffer densification and fracture, debonding between the buffer and inner pyrolytic carbon (IPyC) layers, and fractures in the IPyC and SiC layers. Three basic particle morphologies were established according to the extent of bonding between the buffer and IPyC layers: complete debonding along the interface (Type A), no debonding along the interface (Type B), and partial debonding (Type AB). These basic morphologies were subdivided according to whether the buffer stayed intact or fractured. The resulting six characteristic morphologies were used to classify particles within each cross section, but no spatial patterns were clearly observed in any of the cross-sectional morphology maps. Although positions of particle types appeared random within compacts, examining a total of 830 classified particles allowed other relationships among morphological types to be established.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2012

Ceramographic Examinations of Irradiated AGR-1 Fuel Compacts

The AGR-1 experiment involved irradiating 72 cylindrical fuel compacts containing tri-structural isotropic (TRISO)-coated particles to a peak burnup of 19.5% fissions per initial metal atom with no in-pile failures observed out of almost 300,000 particles. Six irradiated AGR 1 fuel compacts were selected for microscopy that span a range of irradiation conditions (temperature, burnup, and fast fluence). These six compacts also included all four TRISO coating variations irradiated in the AGR experiment. The six compacts were cross-sectioned both transversely and longitudinally, mounted, ground, and polished after development of careful techniques for preserving particle structures against preparation damage. From 36 to 79 particles within each cross section were exposed near enough to midplane for optical microscopy of kernel, buffer, and coating behavior. The microstructural analysis focused on kernel swelling and porosity, buffer densification and fracture, debonding between the buffer and inner pyrolytic carbon (IPyC) layers, and fractures in the IPyC and SiC layers. Three basic particle morphologies were established according to the extent of bonding between the buffer and IPyC layers: complete debonding along the interface (Type A), no debonding along the interface (Type B), and partial debonding (Type AB). These basic morphologies were subdivided according to whether the buffer stayed intact or fractured. The resulting six characteristic morphologies were used to classify particles within each cross section, but no spatial patterns were clearly observed in any of the cross-sectional morphology maps. Although positions of particle types appeared random within compacts, examining a total of 931 classified particles allowed other relationships among morphological types to be established.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2015

Post-Service Examination of PWR Baffle Bolts, Part I. Examination and Test Plan

In support of extended service and current operations of the US nuclear reactor plants, the Oak Ridge National Laboratory (ORNL), through the Department of Energy (DOE), Light Water Reactor Sustainability (LWRS) Program, is coordinating with Ginna Nuclear Power Plant, The Westinghouse Electric Company, LLC, and ATI Consulting, the selective procurement of baffle bolts that were withdrawn from service in 2011 and currently stored on site at Ginna. The goal of this program is to perform detailed microstructural and mechanical property characterization of baffle former bolts following in-service exposures. This report outlines the selection criteria of the bolts and the techniques to be used in this study. The bolts available are the original alloy 347 steel fasteners used in holding the baffle plates to the baffle former structures within the lower portion of the pressurized water reactor vessel. Of the eleven possible bolts made available for this work, none were identified to have specific damage. The bolts, however, did show varying levels of breakaway torque required in their removal. The bolts available for this study varied in peak fluence (highest dose within the head of the bolt) between 9.9 and 27.8x10 21 n/cm 2 (E>1MeV). As no evidence for crack initiation was determined for the available bolts from preliminary visual examination, two bolts with the higher fluence values were selected for further post-irradiation examination. The two bolts showed different breakaway torque levels necessary in their removal. The information from these bolts will be integral to the LWRS program initiatives in evaluating end of life microstructure and properties. Furthermore, valuable data will be obtained that can be incorporated into model predictions of long-term irradiation behavior and compared to results obtained in high flux experimental reactor conditions. The two bolts selected for the ORNL study will be shipped to Westinghouse with bolts of interest to their collaborative efforts with the Electric Power Research Institute. Westinghouse will section the ORNL bolts into samples specified in this report and return them to ORNL. Samples will include bend bars for fracture toughness and crack propagation studies along with thin sections from which specimens for bend testing, subscale tensile and microstructural analysis can be obtained. Additional material from the high stress concentration region at the transition between the bolt head and shank will also be preserved to allow for further investigation of possible crack initiation sites.

42 ENGINEERING↗
DOE OSTI2015

Study of Compatibility of Stainless Steel Weld Joints with Liquid Sodium-Potassium Coolants for Fission Surface Power Reactors for Lunar and Space Applications

To make a manned mission to the surface of the moon or to Mars with any significant residence time, the power requirements will make a nuclear reactor the most feasible source of energy. To prepare for such a mission, NASA has teamed with the DOE to develop Fission Surface Power technology with the goal of developing viable options. The Fission Surface Power System (FSPS) recommended as the initial baseline design includes a liquid metal reactor and primary coolant system that transfers heat to two intermediate liquid metal heat transfer loops. Each intermediate loop transfers heat to two Stirling heat exchangers that each power two Stirling converters. Both the primary and the intermediate loops will use sodium-potassium (NaK) as the liquid metal coolant, and the primary loop will operate at temperatures exceeding 600°C. The alloy selected for the heat exchangers and piping is AISI Type 316L stainless steel. The extensive experience with NaK in breeder reactor programs and with earlier space reactors for unmanned missions lends considerable confidence in using NaK as a coolant in contact with stainless steel alloys. However, the microstructure, chemical segregation, and stress state of a weld leads to the potential for corrosion and cracking. Such failures have been experienced in NaK systems that have operated for times less than the eight year goal for the FSPS. For this reason, it was necessary to evaluate candidate weld techniques and expose welds to high-temperature, flowing NaK in a closed, closely controlled system. The goal of this project was to determine the optimum weld configuration for a NaK system that will withstand service for eight years under FSPS conditions. Since the most difficult weld to make and to evaluate is the tube to tube sheet weld in the intermediate heat exchangers, it was the focus of this research. A pumped loop of flowing NaK was fabricated for exposure of candidate weld specimens at temperatures of 600°C, the expected temperature within the intermediate heat exchangers. Since metal transfer from a high-temperature region to a cooler region is a predominant mode of corrosion in liquid metal systems, specimens were placed at zones in the loop at the above temperature to evaluate the effects of both alloy component leaching and metal deposition. Microstructural analysis was performed to evaluate weld performance on control weld specimens. The research was coordinated with Oak Ridge National Laboratory (ORNL) where most of the weld samples were prepared. In addition, ORNL participated in the loop operation to assist in keeping the testing relevant to the project and to take advantage of the extensive experience in liquid metal research at ORNL.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2015

Evaluation on the Effect of Composition on Radiation Hardening and Embrittlement in Model FeCrAl Alloys

This report details the findings of post-radiation mechanical testing and microstructural characterization performed on a series of model and commercial FeCrAl alloys to assist with the development of a cladding technology with enhanced accident tolerance. The samples investigated include model alloys with simple ferritic grain structure and two commercial alloys with minor solute additions. These samples were irradiated in the High Flux Isotope Reactor (HFIR) at Oak Ridge National Laboratory (ORNL) up to nominal doses of 7.0 dpa near or at Light Water Reactor (LWR) relevant temperatures (300-400 C). Characterization included a suite of techniques including small angle neutron scattering (SANS), atom probe tomography (APT), and transmission based electron microscopy techniques. Mechanical testing included tensile tests at room temperature on sub-sized tensile specimens. The goal of this work was to conduct detailed characterization and mechanical testing to begin establishing empirical and/or theoretical structure-property relationships for radiation-induced hardening and embrittlement in the FeCrAl alloy class. Development of such relationships will provide insight on the performance of FeCrAl alloys in an irradiation environment and will enable further development of the alloy class for applications within a LWR environment. A particular focus was made on establishing trends, including composition and radiation dose. The report highlights in detail the pertinent findings based on this work. This report shows that radiation hardening in the alloys is primarily composition dependent due to the phase separation in the high-Cr FeCrAl alloys. Other radiation induced/enhanced microstructural features were less dependent on composition and when observed at low number densities, were not a significant contributor to the observed mechanical responses. Pre-existing microstructure in the alloys was found to be important, with grain boundaries and pre-existing dislocation networks acting as defect sinks, resulting in variations in the observed microstructures after irradiation. Dose trends were also observed, with increasing radiation dose promoting changes in the size and number density of the Cr-rich α' precipitates. Based on the microstructural analysis, performed tensile testing, and prior knowledge from FeCr literature it was hypothesized that the formation of the Cr-rich α' precipitates could lead to significant radiation-induced embrittlement in the alloys, and this could be composition dependent, a result which would mirror the trends observed for radiation-induced hardening. Due to the limited database on embrittlement in the FeCrAl alloy class after irradiation, a series of radiation experiments have been implemented. The overarching point of view within this report is the radiation tolerance of FeCrAl is complex, with many mechanisms and factors to be considered at once. Further development of the FeCrAl alloy class for enhanced accident tolerant applications requires detailed, single (or at least limited) variable experiments to fully comprehend and predict the performance of this alloy in LWRs. This report has been submitted as fulfillment of milestone M2FT-15OR0202321 titled, Summary report on the effect of composition on the irradiation embrittlement of Gen 1 ATF FeCrAl for the Department of Energy Office of Nuclear Energy, Advanced Fuel Campaign of the Fuel Cycle R&D program.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Nanoindentation of Electropolished FeCrAl Alloy Welds

The present report summarizes Berkovich nanoindentation modulus and hardness measurements on two candidate FeCrAl alloys (C35M and C37M) on as-received (AR) and welded samples. In addition, spherical nanoindentation stress-strain measurements were performed on individual grains to provide further information and demonstrate the applicability of these protocols to mechanically characterizing welds in FeCrAl alloys. The indentation results are compared against the reported tensile properties for these alloys to provide relationships between nanoindentation and tensile tests and insight into weldsoftening for these FeCrAl alloys. Hardness measurements revealed weld-softening for both alloys in good agreement with tensile test results. C35M showed a larger reduction in hardness at the weld center from the AR material compared to C37M; this is also consistent with tensile tests. In general, nanohardness was shown to be a good predictor of tensile yield strength and ultimate tensile stress for FeCrAl alloys. Spherical nanoindentation measurements revealed that the fusion zone (FZ) + heat affected zone (HAZ) has a very low defect density typical of well-annealed metals as indicated by the frequent pop-in events. Spherical nanoindentation yield strength, Berkovich hardness, and tensile yield strength measurements on the welded material all show that the C37M welded material has a higher strength than C35M welded material. From the comparison of nanoindentation and tensile tests, EBSD microstructure analysis, and information on the processing history, it can be deduced that the primary driver for weld-softening is a change in the defect structure at the grain-scale between the AR and welded material. These measurements serve as baseline data for utilizing nanoindentation for studying the effects of radiation damage on these alloys.

36 MATERIALS SCIENCE↗