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At least 685 records · Page 38

Evolution of Microstructure and Surface Characteristics of FeCrAl alloys when Subjected to Flow Boiling Testing

FeCrAl alloys are candidate materials for manufacturing accident-tolerant fuel (ATF) cladding intended for light water reactors to increase fuel reliability and safety during design-basis and beyond-design-basis accident scenarios. The evolution of the materials' surface characteristics, microstructure, and mechanical properties when exposed to the Critical Heat Flux (CHF) in flow boiling testing is crucial for safety analysis while providing insights into their thermal-hydraulic performance in nuclear reactors. After CHF, the surface chemistry of two FeCrAl alloys, APMT and C26M, was studied to understand their evolution at the early stage of high-temperature excursions in short time periods. The results indicated a thin layer composed of oxides and hydroxides of Al, Cr, and Fe with varying proportions at different depths in the layer, as indicated by X-ray photoelectron spectroscopy (XPS) and depth profiling. The cross-sections prepared by focused ion beam (FIB) revealed the growth of an oxide layer, in the range of 90-180 nm thick, on the alloys' surfaces. The evolution of the materials' surface chemistry also led to a noticeable post CHF excursion increase in their wettability, with a slight increase in roughness. Further, the investigation of the materials' mechanical properties indicated a modest increase in hardness by 10-15% as well as an increase in their yield strength, as evidenced by the microindentation and ring compression tests conducted before and after CHF testing. Scanning electron Microscopy (SEM) and X-ray diffraction (XRD) were used to investigate microstructural features of the materials and their changes after CHF treatment.

36 MATERIALS SCIENCE↗

Self-Assembled Framework Formed During Lithiation of SnS 2 Nanoplates Revealed by in Situ Electron Microscopy

Lithium-ion batteries (LIBs) commercially dominate portable energy storage and have been extended to hybrid/electric vehicles by utilizing electrode materials with enhanced energy density. However, the energy density and cycling life of LIBs must extend beyond the current reach of commercial electrodes to meet the performance requirements for transportation applications. Carbon-based anodes, serving as the main negative electrodes in LIBs, have an intrinsic capacity limitation due to the intercalation mechanism. Some nanostructured carbon materials offer very interesting reversible capacities and can be considered as future anode materials. However, their fabrication processes are often complicated and expensive. Theoretically, using a lithium metal anode is the best way of delivering high energy density due to its largest theoretical capacity of more than 3800 mAh g -1 ; however, lithium metal is highly reactive with liquid electrolytes. Alternative anodes are being explored, including other lithium-reactive metals, such as Si, Ge, Zn, V, and so forth. These metals react reversibly with a large amount of Li per formula unit to form lithium–metal alloys, rendering these materials promising candidates for next-generation LIBs with high energy density. Though, most of these pure metallic anodes experience large volume changes during lithiation and delithiation processes that often results in cracking of the anode material and a loss electrical contact between the particles.Nanosized metal sulfides were recently found to possess better cycling stability and larger reversible capacities over pure metals. Further improvements and developments of metal sulfide-based anodes rely on a fundamental understanding of their electrochemical cycling mechanisms. Not only must the specific electrochemical reactions be correctly identified, but also the microstructural evolution upon electrochemical cycling, which often dictates the cyclability and stability of nanomaterials in batteries, must be clearly understood. Probing these dynamic evolution processes, i.e. the lithiation reactions and morphology evolutions, are often challenging. It requires both high-resolution chemical analysis and microstructural identification. In situ transmission electron microscopy (TEM) coupled with electron energy loss spectroscopy (EELS) has recently been raised as one of the most powerful techniques for monitoring electrochemical processes in anode materials for LIBs.In this work, we focus on elucidating the origin of the structural stability of SnS 2 during electrochemical cycling by revealing the microstructural evolution of SnS 2 upon lithiation using in situ TEM. Crystalline SnS 2 was observed to undergo a two-step reaction after the initial lithium intercalation: (1) irreversible formation of metallic tin and amorphous lithium sulfide and (2) reversible transformation of metallic tin to Li–Sn alloys, which is determined to be the rate-determining step. More interestingly, it was discovered that a self-assembled composite framework formed during the irreversible conversion reaction, which has not been previously reported. Crystalline Sn nanoparticles are well arranged within an amorphous Li 2 S “matrix” in this self-assembled framework. This nanoscale framework confines the locations of individual Sn nanoparticles and prevents particle agglomeration during the subsequent cycling processes, therefore providing desired structural tolerance and warranting a sufficientelectron pathway. Finally, our results not only explain the outstanding cycling stability of SnS 2 over metallic tin anodes, but also provide important mechanistic insights into the design of high-performance electrodes for next-generation LIBs through the integration of a unique nanoframework.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Comparison of excess free energy at an interface according to the applied interpolation scheme for elasticity: A phase-field method

Phase-field modeling is an effective simulation technique for modeling microstructure evolution of elastically anisotropic systems. To introduce the elastic energy contribution in a phase field model, an interpolation scheme is used to define the mechanical properties within the phases and across the continuous interface. Several existing interpolation schemes introduce a potential excess elastic energy at the interface, which undesirable effect on microstructure evolution needs to be evaluated. In this study, we focused on three interpolation schemes including Khachaturyan’ scheme (KHS), Voigt–Taylor’s scheme (VTS), and Steinbach–Apel’s scheme (SAS). Comparisons of these schemes’ performances were performed in three configuration types using the MOOSE (Multiphysics Object-Oriented Simulation Environment) framework: bi-crystal, isotropic particle-matrix and anisotropic particle-matrix. The contribution of excess elastic energy on the interface energy as a function of interface width and the computational time to steady-state were evaluated in these three configurations. SAS introduces the lowest excess elastic energy contribution and the VTS has the biggest contribution amongst the considered schemes. Moreover, when modeling precipitation in an anisotropic elastic material, the SAS approach seems to predict more physical convex shapes during growth, making it preferable to KHS and VTS. Finally, as currently implemented, SAS requires the largest computational time and KHS requires the smallest time to reach steady-state amongst the considered schemes.

36 MATERIALS SCIENCE↗

The effects of introducing elasticity using different interpolation schemes to the grand potential phase field model

Introducing elastic energy in the phase field method has been shown to influence interfacial energy, depending on the elastic interpolation scheme. This study investigates the impact of the elastic energy when using a grand potential-based phase field method, comparing the result of Khachaturyan’s strain interpolation scheme (KHS) and Voight-Taylor’s elastic energy interpolation scheme (VTS). The KHS model leads to a decrease in the interfacial energy, while the VTS model leads to an increase. The change in interfacial energy is greater with the VTS model than the KHS model, which suggests that the KHS model is more appropriate to limit the artificial impact of the elastic energy on the interfacial energy. When the contribution at the interface is not negligible, it is shown that both the microstructure evolution kinetics and the equilibrium microstructure can be influenced by the choice of the elastic scheme being used. In addition, this paper shows that the grand potential model might not be appropriate when the system requires the introduction of a composition-dependent term in the elastic energy contribution. This limitation is due to the need for an explicit and invertible relation between the total potential and the composition.

36 MATERIALS SCIENCE↗

Recrystallization driven softening and heating rate dependencies of FeCrAl nuclear fuel cladding during accident transients

A refined understanding of FeCrAl cladding behavior during rapid transients is critical for its potential deployment in light-water reactors. Current assessments focus on transient burst testing metrics such as balloon geometry, burst temperature, and hoop stress, often used as proxies for simpler conventional tensile properties. However, directly correlating isothermal tensile and creep data with accident transient scenarios remains a challenge, although it is essential for high fidelity model development. Recent modeling based on tensile tests up to 800 °C, conducted with both immediate loading and a 10-minute soak, showed that immediate loading better predicts experimental burst temperatures, indicating a thermal softening effect. Building upon this observation, the current study connects transient performance, microstructural evolution, and high-temperature tensile properties by leveraging results from C26M claddings burst tests performed at heating rates of 1–50 °C/s and hoop stresses from 25 to 100 MPa. At 25 MPa, rupture temperatures varied by only 6 °C, but at 100 MPa, the difference reached 116 °C, with faster heating yielding higher burst temperatures. Microstructural analysis identified recrystallization as the primary cause of heating rate-dependent softening, eliminating prior cold-working. In-situ thermomechanical data linked ballooning onset to localized instabilities, similar to ultimate tensile strength behavior in conventional tensile tests. High heating rates correlated with immediate loading tensile data, while lower rates matched soaked data. Furthermore, by linking burst performance to microstructural evolution and tensile properties, this work provides a foundation for more accurate modeling of FeCrAl claddings and potentially other Fe-based materials under accident conditions.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Kink mechanism in Cu/Nb nanolaminates explored by $\mathcal{in}$ $\mathcal{situ}$ pillar compression

We report Nano metallic laminates (NMLs) exhibit different failure modes depending on the loading conditions due to their mechanical anisotropies. Kinking is a typical failure mode in many NMLs compressed along a layer-parallel direction. However, a detailed description of the microstructure evolution during kink band (KB) formation and an in-depth understanding of the formation mechanisms are lacking. In this work, the KB process is investigated in Cu/Nb NMLs by in situ micro pillar compression in the scanning electron microscope (SEM) along a layer-parallel direction. Post-mortem S/TEM and transmission Kikuchi diffraction (TKD) analyses show that kink banding leads to significant microstructure changes characterized by an accumulation of geometrically necessary dislocations (GNDs) and of tilt geometrically necessary boundaries (GNBs) near KB boundaries (KBBs). The distinct microstructure evolution implies that KB formation is facilitated by the inhomogeneous microstructures resulting in constrained deformation modes. Specifically, dislocations active on slip planes nearly parallel to the interfaces make a major contribution to kink evolution after the onset of kinking. Once layer-parallel slip systems are activated, preexisting lattice dislocations and dislocations nucleating from interfaces will accumulate as GNDs near KBBs via the stochastic storage of lattice dislocations that have certain Burgers vectors. GNDs can further transform into GNBs via cross-slip and climb driven processes near the KBB. Furthermore, GNBs near KBBs can grow by incorporating more GNDs or by coalescence to accommodate the KB evolution. We further hypothesize that microstructural perturbations and their ensuing stresses can initiate KB formation in Cu/Nb NMLs.

36 MATERIALS SCIENCE↗

Modeling defect cluster evolution in irradiated structural materials: Focus on comparing to high-resolution experimental characterization studies

Exposure of metallic structural materials to irradiation environments results in significant microstructural evolution, property changes, and performance degradation, which limits the extended operation of current generation light water reactors and restricts the design of advanced fission and fusion reactors. Further, it is well recognized that these irradiation effects are a classic example of inherently multiscale phenomena and that the mix of radiation-induced features formed and the corresponding property degradation depend on a wide range of material and irradiation variables. This inherently multiscale evolution emphasizes the importance of closely integrating models with high-resolution experimental characterization of the evolving radiation-damaged microstructure. Lastly, this article provides a review of recent models of the defect microstructure evolution in irradiated body-centered cubic materials, which provide good agreement with experimental measurements, and presents some outstanding challenges, which will require coordinated high-resolution characterization and modeling to resolve.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗

Matching time and spatial scales of rapid solidification: Dynamic TEM experiments coupled to CALPHAD-informed phase-field simulations

A combination of dynamic transmission electron microscopy (DTEM) experiments and CALPHAD-informed phase-field simulations was used to study rapid solidification in Cu–Ni thin-film alloys. Experiments—conducted in the DTEM—consisted of in situ laser melting and determination of the solidification kinetics by monitoring the solid–liquid interface and the overall microstructure evolution (time-resolved measurements) during the solidification process. Modelling of the Cu–Ni alloy microstructure evolution was based on a phase-field model that included realistic Gibbs energies and diffusion coefficients from the CALPHAD framework (thermodynamic and mobility databases). DTEM and post mortem experiments highlighted the formation of microsegregation-free columnar grains with interface velocities varying from ~0.1 to ~0.6 m s –1 . After an 'incubation' time, the velocity of the planar solid–liquid interface accelerated until solidification was complete. In addition, a decrease of the temperature gradient induced a decrease in the interface velocity. The modelling strategy permitted the simulation (in 1D and 2D) of the solidification process from the initially diffusion-controlled to the nearly partitionless regimes. Lastly, results of DTEM experiments and phase-field simulations (grain morphology, solute distribution, and solid–liquid interface velocity) were consistent at similar time (μs) and spatial scales (μm).

36 MATERIALS SCIENCE↗

Dynamic, robust, radiation-resistant ceramics: harnessing thermodynamic and kinetic driving forces (Final Report)

The overarching objective of this project was to establish a class of structural ceramics with enhanced radiation tolerance based on a dynamic microstructure by harnessing the synergistic effects of radiation enhanced diffusion, capillarity and thermally induced mass transport on microstructural evolution. Specifically, we aimed to quantify changes in mass transport behavior that may influence the microstructural evolution of ionic/covalent ceramic materials subjected to irradiation.

99 GENERAL AND MISCELLANEOUS↗

Analysis of gamma prime shape changes in a single crystal Ni-base superalloy

The microstructural evolution of a commercial single crystal superalloy, NASAIR 100, is analyzed using the existing high-temperature lattice mismatch data and high-temperature moduli obtained from tests on single crystals of gamma and gamma prime. A multiparticle analysis of the microstructural evolution is performed using a novel microstructural lattice simulation technique, MCFET. Under a uniaxial stress, a regular array of gamma prime particles in the simulated microstructure is predicted to coalesce and form a plate morphology, with the broad faces of the plates and stress axis perpendicular in tension but parallel in compression. These results are consistent with changes in gamma prime shape observed in NASAIR 100 following creep testing at 1000 C.

Gayda, J.↗

Mesoscale modeling of solute precipitation and radiation damage

This report summarizes the low length scale effort during FY 2014 in developing mesoscale capabilities for microstructure evolution in reactor pressure vessels. During operation, reactor pressure vessels are subject to hardening and embrittlement caused by irradiation-induced defect accumulation and irradiation-enhanced solute precipitation. Both defect production and solute precipitation start from the atomic scale, and manifest their eventual effects as degradation in engineering-scale properties. To predict the property degradation, multiscale modeling and simulation are needed to deal with the microstructure evolution, and to link the microstructure feature to material properties. In this report, the development of mesoscale capabilities for defect accumulation and solute precipitation are summarized. Atomic-scale efforts that supply information for the mesoscale capabilities are also included.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Lower Length Scale Model Development for Embrittlement of Reactor Presure Vessel Steel

This report summarizes the lower-length-scale effort during FY 2016 in developing mesoscale capabilities for microstructure evolution, plasticity and fracture in reactor pressure vessel steels. During operation, reactor pressure vessels are subject to hardening and embrittlement caused by irradiation induced defect accumulation and irradiation enhanced solute precipitation. Both defect production and solute precipitation start from the atomic scale, and manifest their eventual effects as degradation in engineering scale properties. To predict the property degradation, multiscale modeling and simulation are needed to deal with the microstructure evolution, and to link the microstructure feature to material properties. In this report, the development of mesoscale capabilities for defect accumulation and solute precipitation are summarized. A crystal plasticity model to capture defect-dislocation interaction and a damage model for cleavage micro-crack propagation is also provided.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Enhanced Generic Phase-field Model of Irradiation Materials: Fission Gas Bubble Growth Kinetics in Polycrystalline UO 2

Experiments show that inter-granular and intra-granular gas bubbles have different growth kinetics which results in heterogeneous gas bubble microstructures in irradiated nuclear fuels. A science-based model predicting the heterogeneous microstructure evolution kinetics is desired, which enables one to study the effect of thermodynamic and kinetic properties of the system on gas bubble microstructure evolution kinetics and morphology, improve the understanding of the formation mechanisms of heterogeneous gas bubble microstructure, and provide the microstructure to macroscale approaches to study their impact on thermo-mechanical properties such as thermo-conductivity, gas release, volume swelling, and cracking. In our previous report 'Mesoscale Benchmark Demonstration, Problem 1: Mesoscale Simulations of Intra-granular Fission Gas Bubbles in UO 2 under Post-irradiation Thermal Annealing', we developed a phase-field model to simulate the intra-granular gas bubble evolution in a single crystal during post-irradiation thermal annealing. In this work, we enhanced the model by incorporating thermodynamic and kinetic properties at grain boundaries, which can be obtained from atomistic simulations, to simulate fission gas bubble growth kinetics in polycrystalline UO 2 fuels. The model takes into account of gas atom and vacancy diffusion, vacancy trapping and emission at defects, gas atom absorption and resolution at gas bubbles, internal pressure in gas bubbles, elastic interaction between defects and gas bubbles, and the difference of thermodynamic and kinetic properties in matrix and grain boundaries. We applied the model to simulate gas atom segregation at grain boundaries and the effect of interfacial energy and gas mobility on gas bubble morphology and growth kinetics in a bi-crystal UO 2 during post-irradiation thermal annealing. The preliminary results demonstrate that the model can produce the equilibrium thermodynamic properties and the morphology of gas bubbles at grain boundaries for given grain boundary properties. More validation of the model capability in polycrystalline is underway.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

A scalable framework for efficient coupling of thermal and microstructural simulations in additive manufacturing

Predicting microstructure evolution in metal additive manufacturing (AM) is important for process optimization, but spatiotemporal scale disparities between thermal transport and microstructure evolution create significant challenges for efficient data transfer between simulation codes. To address this, we present Stork, a scalable framework for coupling thermal and microstructural simulations. Stork uses a sparse data representation to identify and store active solidification sub-volumes, enabling highly parallel quad-linear interpolation from coarse thermal grids to fine microstructure grids without large intermediate storage. We demonstrate the framework by coupling the semi-analytic heat transfer code 3DThesis with the time-parallel cellular automata code Toucan. This approach achieves over two orders of magnitude reduction in data generation time and file size compared to prior workflows. Numerical studies show that quad-linear interpolation preserves grain morphology and crystallographic texture in laser powder bed fusion (LPBF) simulations for coarsening ratios up to 16. Overall, Stork provides a scalable pathway for high-throughput, component-scale AM simulations on modern high-performance computing systems.

36 MATERIALS SCIENCE↗

Evolution of the role of molybdenum in duplex stainless steels during thermal aging: From enhancing spinodal decomposition to forming heterogeneous precipitates

Thermal aging of ferrite in duplex stainless steels leads to a complex microstructural evolution that can give way to large deleterious changes in mechanical properties. The microstructural evolution mechanisms that happen concurrently are strongly linked to minor changes in composition. By characterizing duplex stainless steels with various compositions over a range of aging conditions, it was revealed that adding a modest amount of Mo to cast austenitic stainless steel (such as changing from grade CF3 to grade CF3M) not only increases the kinetics of spinodal decomposition and Ni-Si-Mn-rich G-phase precipitation, but it also forms a separate Mo-rich phase. At shorter equivalent aging times, Mo segregates from Fe and towards Cr accelerating spinodal decomposition. At longer aging times, Mo enriches in the Ni-Si-Mn clusters before phase separating into an adjoined Mo-rich cluster. We found that these phase changes and precipitation events result in a rather steep drop in fracture and impact toughness. These results will inform the design of similar alloys for use at high temperatures.

36 MATERIALS SCIENCE↗

Oxidation and microstructure of SiC f /SiC composites in moist air up to 1600°C by X‐ray tomographic characterization

Abstract SiC f /SiC composites that possess PyC or BN interface layers were fabricated and then oxidized in moist air at 1000, 1200, 1400, and 1600°C. High‐resolution CT was used for capturing 3D images and quantifying the SiC phase, mesophase, and voids. The oxidation behavior and microstructural evolution of SiC f /SiC with PyC or BN interface are discussed in this study. The microstructure of the SiC f /SiC with a PyC layer was seriously damaged in moist air at high temperature, whereas the BN interface layer enhanced the oxidation resistance of the SiC f /SiC. These results are also confirmed by using XRD, oxidation mass gain, tensile testing, and SEM measurements. The results of the oxidation behavior and microstructural evolution for SiC f /SiC oxidized in dry air are also compared with the results of this study. Comparing the SiC f /SiC with a PyC interface layer, the composite with a BN interface layer oxidized in moist air exhibits a high void growth rate and a low SiO 2 grain growth rate from 1000 to 1600°C. This work will provide guidance for predicting the service life of SiC f /SiC for multiscale damage rate models of materials at a local scale and will also provide guidance on the life service design of SiC f /SiC materials.

Lu, Zilong↗

Linking Initial Microstructure to ORR Related Property Degradation in SOFC Cathode: A Phase Field Simulation

Microstructure evolution driven by thermal coarsening is an important factor for the loss of oxygen reduction reaction rates in SOFC cathode. In this work, the effect of an initial microstructure on the microstructure evolution in SOFC cathode is investigated using a recently developed phase field model. Specifically, we tune the phase fraction, the average grain size, the standard deviation of the grain size and the grain shape in the initial microstructure, and explore their effect on the evolution of the grain size, the density of triple phase boundary, the specific surface area and the effective conductivity in LSM-YSZ cathodes. It is found that the degradation rate of TPB density and SSA of LSM is lower with less LSM phase fraction (with constant porosity assumed) and greater average grain size, while the degradation rate of effective conductivity can also be tuned by adjusting the standard deviation of grain size distribution and grain aspect ratio. The implication of this study on the designing of an optimal initial microstructure of SOFC cathodes is discussed.

25 ENERGY STORAGE↗

Mechanisms for stabilizing θ'(Al 2 Cu) precipitates at elevated temperatures investigated with phase field modeling

While most Al–Cu and Al–Si–Cu alloys strengthened by the metastable θ' phase exhibit extensive microstructural degradation above 200 °C, recent experimental work has demonstrated that θ' precipitates can be stabilized to 350 °C by microalloying additions of Mn and Zr, resulting in improved mechanical properties at elevated temperatures. Here, the present work utilizes phase field modeling to study the relationship between microalloying solute elements and the coarsening resistance of θ'. Simulations are designed to parse out the relative influence of various stabilization mechanisms on microstructural evolution of θ' precipitates at elevated temperatures. Specifically, a ternary alloying element is added to a virtual microstructure to study the operation and effectiveness of stabilization mechanisms including solute drag, diffusion barriers, interfacial energy reduction, and lattice strain modification. Simulation results are compared with atom probe tomography observations. Lastly, the simulations rationalize experimental observations of microstructural evolution and solute segregation in Al–Cu–Mn–Zr alloys, and reveal the interlinked thermodynamic and kinetic mechanisms that determine the elevated temperature stability of θ' precipitates.

36 MATERIALS SCIENCE↗