Advanced Materials and Manufacturing Technologies (AMMT) 2022 Roadmap
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Li, Meimei↗
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Material Developments for 3D/4D Additive Manufacturing (AM) Technologies
Additive Manufacturing (AM), or 3D printing, is a unique technology in which structurally complex objects can be easily manufactured. While AM allows for the creation of intricate 3D objects, these objects are inactive and motionless. With recent incorporation of a “pre-programmed functionality’’ to the 3D printed objects, a new concept has emerged, 4D printing. Specifically, the 4D printing technology enables a static 3D printed object to change its shape, functionality or property over time upon exposure to a specific stimulus such as heat, stress, light, pH, and moisture, etc. We designed and produced compact 3D/4D printable materials that can be used as (a) structural components of the unmanned aerial vehicles (UAVs), and (b) as hydrogen storage materials that supply hydrogen to a fuel cell to expand the operational reach, namely flight time, and endurance of the UA Vs.
36 MATERIALS SCIENCE↗
Material Developments for 3D/4D Additive Manufacturing (AM) Technologies
Additive Manufacturing (AM), or 3D printing, is a unique technology in which structurally complex objects can be easily manufactured. While AM allows for the creation of intricate 3D objects, these objects are inactive and motionless. With recent incorporation of a “pre-programmed functionality” to the 3D printed objects, a new concept has emerged, 4D printing. Specifically, the 4D printing technology enables a static 3D printed object to change its shape, functionality or property over time upon exposure to a specific stimulus such as heat, stress, light, pH, and moisture, etc. We designed and produced compact 3D/4D printable materials that can be used as (a) structural components of the unmanned aerial vehicles (UAVs), and (b) as hydrogen storage materials that supply hydrogen to a fuel cell to expand the operational reach, namely flight time, and endurance of the UAVs.
08 HYDROGEN↗
Clean Energy Manufacturing: Renewable Energy Technology Benchmarks
The manufacturing of clean energy technologies has become a global enterprise. An analysis of four clean energy technology manufacturing processes—wind turbine components, crystalline silicon solar photovoltaic modules, light-duty vehicle lithium-ion battery cells, and light-emitting diodes—was conducted to provide a reference point for comparison over time as this sector evolves. The manufacturing supply chain analysis included processing of raw materials, making required subcomponents, and assembling final products, using benchmarks that crossed 12 economies: Brazil, Canada, China, Germany, India, Japan, Malaysia, Mexico, South Korea, Republic of China (Taiwan), the United Kingdom, and the United States. Larger economies, with extensive manufacturing supply chains and high prevailing wages, tend to retain more value added from clean energy manufacturing than small economies. Manufacturing of clean energy technologies drives extensive trade among economies to support the widely distributed supply chain links. Production of wind turbine components and photovoltaic modules is more centralized than production of light-emitting diodes and lithium-ion battery cells. Across the four clean energy technologies evaluated, there was generally an excess of manufacturing capacity relative to global supply.
benchmarks↗
In-Situ Monitoring Assisted Large-Scale Additive Manufacturing of Mild Steel and 316L Alloys for Nuclear Application
The Advanced Materials and Manufacturing Technologies (AMMT) Program is aimed at developing cross-cutting technologies in support of a broad range of nuclear reactor parts, and to maintain U.S. leadership in materials and manufacturing technologies for nuclear energy applications. The overarching vision of the AMMT program is to accelerate the development, qualification, demonstration and deployment of advanced materials and manufacturing technologies to enable reliable and economical nuclear energy. One of its three goals is to target big challenges and game-changing technologies, to realize the mission and vision of AMMT program. Based on this context, this multi-year work package focuses on understanding the current state of large-scale additive manufacturing (AM) technology for the deposition of 316L stainless steel materials for final components and mild steel for use in nuclear manufacturing processes. The targeted AM modality is directed energy deposition (DED), capable of fabricating components on the size scale of meters including valves, pumps, impellers. etc. that are challenging or difficult to source, especially when developing new systems or replacing obsolete components. Accordingly, the current writeup aims at providing a baseline literature survey on structure-property relationships in mild steel and 316L alloys. Also, information on preliminary trials to date involving these two alloys show tremendous potential of printing parts having complex geometry and thin- walled structures, such as nuclear valve and Hot isostatic Press (HIP) can, using wire based (Wire Arc Additive Manufacturing and Hybrid Additive Manufacturing) as well as blown powder DED machines. All of this is aimed towards (i) demonstrating the ability to fabricate large components for pressure boundary applications relevant to the nuclear community and nuclear manufacturing technology, and (ii) understanding the effect of different manufacturing technology on AM can production and post HIPed material for nuclear applications. Another target of this writeup is to compile various in-situ monitoring tools that have been incorporated for different DED AM modalities, in order to understand process variability during the entire fabrication process. This can be correlated with processing-structure-property response surfaces and would add confidence around process quality verification and ultimately component certification for nuclear applications.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
Initial Results of PostProcess NDE Using Advanced Techniques
The U.S. Department of Energy, Office of Nuclear Energy Advanced Materials and Manufacturing Technologies Program is developing advanced materials and manufacturing technologies that will enable the safe and economical operation of both the current fleet and the next generation of advanced nuclear reactors. Post-process nondestructive evaluation capabilities are a key enabling technology that will be required to qualify and verify the condition of components produced using advanced materials and manufacturing technologies.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
Preliminary Characterization and Evaluation on FFF Manufactured 316H and ODS Steels
The Advanced Materials and Manufacturing Technology (AMMT) program develops cross-cutting technologies in support of a broad range of nuclear reactor technologies and maintains U.S. leadership in materials and manufacturing technologies for nuclear energy applications. The overarching vision of AMMT is to accelerate the development, qualification, demonstration, and deployment of advanced materials and manufacturing technologies to enable reliable and economical nuclear energy. Solid-state advanced manufacturing techniques can overcome some of the challenges in liquid-based additive manufacturing (AM) processes and should therefore be considered in material design and manufacturing as well. The work presented in this report forms part of a study on solid-state AM techniques of 316 stainless steels (SS) and oxide dispersion strengthened (ODS) steel components and supports the vision and goals of the AMMT program relevant to accelerate the development and deployment of advanced manufacturing processes. Achieving this can provide a safety improvement through larger safety margins, economic benefit for higher efficiency during operation, and a cost reduction through more effective manufacturing processes and less waste. This study provides preliminary information on development of the fused-filament fabrication (FFF) process using different powder types to demonstrate the sensitivity, and therefore the characterization of these sample components. The full solid-state manufacturing feasibility study will be completed and reported in a final feasibility evaluation during 2025. The study investigation used two 14YWT ODS powder batches, which provided information and the effect of different powder morphologies on manufacturability. The two 316SS powders demonstrated the effect of powder size on the manufacturability using FFF. Two product forms, namely a honeycomb structure and flat samples, were manufactured to demonstrate the flexibility of product form.
36 MATERIALS SCIENCE↗
Preliminary Characterization and Evaluation on ShAPE Manufactured 316H and ODS Steels
This study provides the first- of- a- kind results of direct tube formation through shear assisted processing and extrusion (ShAPE) for oxide dispersion strengthened (ODS) steel material; previously only bar was successfully made. The Advanced Materials and Manufacturing Technology (AMMT) program develops cross-cutting technologies in support of a broad range of nuclear reactor technologies and maintains U.S. leadership in materials and manufacturing technologies for nuclear energy applications. The overarching vision of AMMT is to accelerate the development, qualification, demonstration, and deployment of advanced materials and manufacturing technologies to enable reliable and economical nuclear energy. Solid-state advanced manufacturing techniques can overcome some of the challenges in liquid-based additive manufacturing processes and should therefore be considered in material design and manufacturing as well. The work presented in this report forms part of a study on solid-state additive manufacturing techniques of 316 stainless steels and ODS steel components and supports the vision and goals of the AMMT program relevant to accelerate the development and deployment of advanced manufacturing processes. Achieving this can provide a safety improvement through larger safety margins, economic benefit for higher efficiency during operation, and a cost reduction through more effective manufacturing processes and less waste.
36 MATERIALS SCIENCE↗
Compliant heat exchangers, heat pipes and methods for making same
A method for fabricating heat exchangers using additive manufacturing technologies. Additive manufacturing enables the manufacture of heat exchangers with complex geometries and/or with internal and external integral surface features. Additive manufacture also facilitates the manufacture of heat exchangers with regional variations, such as changes in size, shape and surface features. In one embodiment, the present invention provides a heat exchanger with a helicoidal shape that provides axial elastic compliance. In one embodiment, the internal channel of the heat exchanger varies along its length. The internal channel may have a cross-sectional area that increases progressively from one end to the other. In one embodiment, the external shape of the tubular structure may be non-circular to optimize heat transfer with an external heat transfer fluid. In one embodiment, the present invention provides a heat pipe with an internal wicking structure formed as an integral part of the additive manufacturing process.
Lara-Curzio, Edgar↗
Qualification Framework Evaluations, Status Quo, and Recommendations
The Advanced Materials and Manufacturing Technology (AMMT) program develops cross-cutting technologies in support of a broad range of nuclear reactor technologies and maintains U.S. leadership in materials and manufacturing technologies for nuclear energy applications. The overarching vision of AMMT is to accelerate the development, qualification, demonstration, and deployment of advanced materials and manufacturing technologies to enable reliable and economical nuclear energy. The acceleration of qualification processes is one of the key aspects and qualification processes for the nuclear industry is not necessarily equivalent or benchmarked against other industries.
36 MATERIALS SCIENCE↗
Survey Corrosion Testing Methodologies for Additively Manufactured Materials – PNNL
The Advanced Materials and Manufacturing Technology (AMMT) Program intends to develop cross-cutting technologies in support of a broad range of nuclear reactor technologies, and to maintain U.S. leadership in materials and manufacturing technologies for nuclear energy applications. The overarching vision of the AMMT Program is to accelerate the development, qualification, demonstration, and deployment of advanced materials and manufacturing technologies to enable reliable and economical nuclear energy.
36 MATERIALS SCIENCE↗
Scalability Testing Approach for Internet of Things for Manufacturing SQL and NoSQL Database Latency and Throughput
The proliferation of low-cost sensors and industrial data solutions has continued to push the frontier of manufacturing technology. Machine learning and other advanced statistical techniques stand to provide tremendous advantages in production capabilities, optimization, monitoring, and efficiency. The tremendous volume of data gathered continues to grow, and the methods for storing the data are critical underpinnings for advancing manufacturing technology. This work aims to investigate the ramifications and design tradeoffs within a decoupled architecture of two prominent database management systems (DBMS): sql and NoSQL. A representative comparison is carried out with Amazon Web Services (AWS) DynamoDB and AWS Aurora MySQL. The technologies and accompanying design constraints are investigated, and a side-by-side comparison is carried out through high-fidelity industrial data simulated load tests using metrics from a major US manufacturer. The results support the use of simulated client load testing for comparing the latency of database management systems as a system scales up from the prototype stage into production. As a result of complex query support, MySQL is favored for higher-order insights, while NoSQL can reduce system latency for known access patterns at the expense of integrated query flexibility. Here, by reviewing this work, a manufacturer can observe that the use of high-fidelity load testing can reveal tradeoffs in IoTfM write/ingestion performance in terms of latency that are not observable through prototype-scale testing of commercially available cloud DB solutions.
AWS↗
Bifacial Bake-off: Comparing Technologies and Manufacturers
Presentation of test results from PVEL's bifacial testing with comparisons of module performance by cell technology and manufacturer.
Meydbray, Jenya↗
Interpretation of Ion Irradiation and Neutron Irradiation Damage in Additively Manufactured 316 Stainless Steel using Multiscale Modeling
The accelerated adoption of nuclear energy necessitates advanced manufacturing technologies, such as additive manufacturing, to meet heightened supply chain requirements and support innovative reactor technologies. Due to the unique microstructural characteristics of additively manufactured materials under distinct solidification conditions, comprehensive evaluation of their performance in reactor environments is essential. The Advanced Materials and Manufacturing Technologies program under the Department of Energy's Office of Nuclear Energy focuses on understanding the irradiation performance and damage evolution of laser powder bed fusion 316 stainless steel, with an emphasis on integrating ion and neutron irradiation data to accelerate the development and qualification of materials for advanced nuclear reactor applications. While ion irradiation is a cost- and time-effective method, modeling and simulation are required to interpret the data for the broader range of irradiation conditions encountered in advanced reactors. In fiscal year 2025, integrated multiscale modeling and simulations were conducted to assess irradiation damage in additively manufactured 316 stainless steel. Key outcomes include predictions of chromium enrichment at grain boundaries, nickel enrichment at dislocation cell walls and void surfaces, and heterogeneous void evolution under ion and neutron irradiation conditions. Cluster dynamics simulations revealed the coarsening of voids at high irradiation temperatures and the suppression of void growth by high network dislocation density, while also demonstrating significant growth and coarsening of voids and self-interstitial atom loops at low dose rates. Machine learning-accelerated atomistic simulations highlighted the impact of the local environment and chromium concentration on vacancy diffusivity, providing key insights on the influence of composition on void swelling and radiation-induced segregation. Additionally, molecular dynamics simulations demonstrated the presence of defect production bias and a significant effect of carbon content on defect cluster behavior. These combined efforts aim to predict the performance of additively manufactured materials under various reactor conditions, supporting their qualification for nuclear reactor applications by interpreting ion irradiation data. This report underscores the potential of integrated multiscale modeling to analyze ion irradiation data in the effort to accelerate the qualification of additively manufactured materials for nuclear reactor components.
316 stainless steel↗
Industry 4.0 and Intelligent Manufacturing Processes: A Review of Modern Sensing Technologies
Digital Manufacturing technologies have quickly become ubiquitous in the manufacturing industry. The transformation commonly referred to as the fourth industrial revolution, or Industry 4.0, has ushered in a wide range of communication technologies, connection mechanisms, and data analysis capabilities. These technologies provide powerful tools to create a more lean, profitable, and data-driven manufacturing processes. In this paper, we review modern communication technologies and connection architectures for Digital Manufacturing and Industry 4.0 applications. An introduction to Cyber-Physical Systems and a review of digital manufacturing trends is followed by an overview of data acquisition methods for manufacturing processes. Numerous communication protocols are presented and discussed for connecting disparate machines and processes. Flexible data architectures are discussed and examples of machine monitoring implementations are provided. Finally, select implementations of these communication protocols and architectures are surveyed with recommendations for future architecture implementations.
42 ENGINEERING↗
Dual Phase Soft Magnetic Laminates for Low-cost, Non/Reduced-Rare-Earth Containing Electrical Machines
To accelerate the mass market adoption of electric drive vehicles, the key technology barriers in electric motors are (1) magnet cost and rare-earth element price volatility; (2) non-rare-earth electric motor performance; and (3) materials property optimization. The goal of this project was to address these barriers by advancing a unique and innovative dual phase soft magnetic material technology and demonstrating the material in a 30-kW synchronous reluctance motor without using any permanent magnet for electric vehicles. Dual phase magnetic materials offer the electric motor designer the ability to locally control the magnetic saturation level in a motor laminate, while at the same time enhancing the mechanical strength of the laminate material, resulting in an enhancement in motor performance and efficiency. Scalable dual phase soft magnetic laminates manufacturing technologies were developed in collaboration with multiple US manufacturers. 1000 lbs of alloy sheet with a thickness of 0.25mm and width of 280 mm was manufactured within the specifications. Batch sizes of up to 240 laminates per run were produced from the alloy sheet. Two prototype motors with dual phase soft magnetic laminates were designed, built, and tested. The major goal of building the subscale prototype as a pathway to develop scalable manufacturing technologies for the dual phase soft magnetic laminates was met. The additional goal of building and testing the subscale prototype in order to validate the calculated performance with the tested motor performance was also met. For the full-scale 30kW continuous power synchronous reluctance motor prototype, the tested performance met the targets in terms of continuous power at the operating speeds up to 8000 rpm. Post-test studies were conducted and the root causes for the discrepancy between the predicted and tested peak power, continuous power at high speed range, and efficiency were identified. Further modeling study showed that the dual phase rotor machine has a 27% higher torque to active weight ratio than an equivalent performance silicon steel rotor machine. Application space and multiple discussions with traction motor and electric vehicle manufacturers for commercialization of the dual phase soft magnetic material technology were identified and conducted. An initial cost model was established based on the developed manufacturing technologies with the US manufacturers. Future paths for further cost reduction were identified, including increasing the market volume by broadening the applications of the dual phase soft magnetic laminate technology for electric machines in other energy sections such as oil & gas, heating, ventilation, and air conditioning (HVAC), and power generation.
33 ADVANCED PROPULSION SYSTEMS↗
Evaluation of Directed Energy Deposition and Laser Powder Bed Fusion Nickel-Based Alloys Process Application Envelopes Based on Performance, Process Economics, Supply Chain Risks, and Reactor-Specific Targeted Components
The goal of the Advanced Materials and Manufacturing Technologies (AMMT) program is to accelerate the deployment of new materials and manufacturing technologies into advanced nuclear-related systems. Although 316H stainless steel fabricated by laser powder bed fusion (LPBF) has already been identified as an alloy that could have a significant effect on various reactor technologies, many other materials and manufacturing techniques are being evaluated. Nickel-based alloys typically offer higher-temperature capabilities compared with advanced stainless steels, and previous reports looked at three Ni-based alloy categories: low-Co alloys with a potential use close to the reactor core; high-temperature, high-strength alloys; and molten salt–compatible alloys. Due to the increasing interest in the low Co 625 alloy for nuclear applications, the alloy was compared at the Oak Ridge National Laboratory (ORNL) with 617, 230, two high-temperature, high-strength solution-strengthened alloys. Hot cracking could not be suppressed for alloy 230, and it was shown that these cracks, which were elongated along the build direction (BD), had a drastic effect on the ductility of alloy 230 at room temperature when specimens were machined perpendicular to the BD. Cracking was not as significant for alloy 617, but still led to significant variation in ductility at room temperature along the build direction. On the contrary, LPBF printing of crack-free alloy 625 was achieved using similar printing parameters, and the alloy looks like a very promising candidate for various reactor technologies.
36 MATERIALS SCIENCE↗
Complete Optimization of LPBF Ni-Based Alloys Down-Selected from FY23 Candidate Materials Including, Thermodynamic Modeling, Sample Fabrication and Microstructure Characterization
The goal of the Advanced Materials and Manufacturing Technologies (AMMT) program is to accelerate the incorporation of new materials and manufacturing technologies into advanced nuclear-related systems. Although 316H stainless steel fabricated by laser powder bed fusion (LPBF) has already been identified as an alloy that could have a significant effect on various reactor technologies, many other materials and manufacturing techniques are being evaluated. Nickel-based alloys typically offer higher-temperature capabilities compared with advanced stainless steels, and previous reports looked at three Ni-based alloy categories: low-Co alloys with a potential use close to the reactor core; high-temperature, high-strength alloys; and molten salt–compatible alloys. In the first category, alloy 718 was studied in 2023, and creep testing at 600°C and 650°C revealed that the alloy exhibited great creep strength after the appropriate annealing but had low ductility. Advanced characterization was recently conducted to highlight the presence of strengthening γ' and γ" precipitates after creep testing and to show that brittle phases at grain boundaries might explain the low ductility of LPBF 718 compared with wrought 718. For the high-temperature, high-strength alloys, previously purchased powders of alloys 617, 230, and 625 were used to assess the printability of these three solution-strengthened alloys. Hot cracking could not be suppressed for alloy 617 and 230, and it was shown that these cracks, which were elongated along the build direction (BD), had a drastic effect on the ductility of alloy 230 at room temperature when specimens were machined perpendicular to the BD. On the contrary, LPBF printing of crack-free alloy 625 was achieved using similar printing parameters, and the alloy looked like a promising candidate for various reactor technologies. The fabrication of alloy 282 by LPBF, a γ'-strengthened alloy with great creep strength up to 800°C, was performed in 2023, and x-ray computed tomography (XCT) scans of the alloy before and after creep testing at 750°C were carried out to assess the effect of flaws on the alloy’s creep behavior. Correlation between the flaws’ volume fraction, creep ductility, and creep lifetime could be established, and future work on LPBF 625 will take full advantage of in situ printing data and ex situ XCT scans to accelerate the alloy qualification. Finally, single track experiments were performed on the two alloys previously identified as good molten salt–resistant, Ni-based candidates: Hastelloy N and 244. Various laser parameters were considered, and cracking was not observed for either of the two alloys. Wrought 244 offers better creep strength and molten salt compatibility than alloy 625, and future work will aim to establish the alloy LPBF processing window.
36 MATERIALS SCIENCE↗