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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 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Changes to the morphology and coefficient of thermal expansion in HDPE and UHMWPE following irradiation-based crosslinking

This work describes recent findings of the Los Alamos National Laboratory concerning the alterations to polyethylene’s (PE’s) mechanical and chemical properties after crosslinking via gamma irradiation. Three materials were examined as part of this study, including one HDPE and two UHMWPE specimens. Changes to degree of crystallinity (X C ) were qualitatively determined via measurements of density, and results suggest that X C is not necessarily correlated to crosslink density, depending on polymer manufacturing process and treatment following irradiation. TMA data suggests an anisotropic response in linear thermal expansion, and that the response may be more correlated to X C than crosslink density. Finally, FTIR analysis has led to the conclusion that oxidation occurs as a result of irradiation in open air, the degree of oxidation is proportional to the maximum radiation dose received, and that oxidation is largely a surface effect, penetrating no deeper than 1.5 mm. Due to time constraints, a full dataset could not be generated for changes in creep and thermal properties as a result of irradiation, and TMA analysis is only complete for one material tested in this study. These measurements are ongoing and will provide more context to the hypotheses drawn in this work.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Directed energy deposition of Haynes 282 nickel superalloy

Laser powder directed energy deposition was employed to fabricate Haynes® 282 Ni-based superalloy for high temperature creep testing. Material was heat treated using a single-step aging heat treatment of 800 °C for 4 h. Microstructural analysis was conducted in the as-deposited, solution-annealed, and age-hardened conditions. γ′ precipitates were absent in the as-deposited and annealed condition but formed during aging with an average size of 48.5 ± 12 nm. γ’ denuded zones ranging in thickness from 73 to 469 nm were observed adjacent to an effectively continuous grain boundary carbide film that covered 72.5% of the measured boundary length. The heat-treated material contained a high-volume fraction of TiC carbides ranging in size from 38 to 457 nm. Electron backscatter diffraction showed partial recrystallization, with 77-83% recrystallized area and a heterogeneous grain-size distribution. Creep testing at 750 °C at 300, 320, and 350 MPa revealed significantly inferior performance compared to wrought material, with higher strain rates, earlier tertiary onset, and shorter rupture lives. Fractography shows that failure was dominated by intergranular rupture. Post rupture microstructural analysis results suggest that the creep behavior was primarily governed by the non-equilibrium interface network rather than the bulk γ/γ’ matrix. In conclusion, the findings indicate that achieving wrought-like creep performance necessitates substantial improvements in the additive process, specifically focusing on enhanced homogenization, full recrystallization, and precise control over the morphology and distribution of carbides.

36 - MATERIALS SCIENCE↗
DOE OSTI2025

Creep Behavior of Friction Stir Processed Haynes 282

Haynes 282 is a nickel-based superalloy designed for use in hot sections of turbines for aircraft and power generation. In these applications, elevated temperature creep performance is critical. To that end, creep behavior of friction stir processed material was carried out to investigate the high-temperature performance of this alloy. Friction stir processing of Haynes 282 was successfully completed, and the processed region was found to be defect-free. Various mechanical property characterization approaches were carried out in post-heat treated condition. Transverse tensile samples repeatedly failed in the base metal indicating 100% joint efficiency. Creep property evaluation was completed at 760 °C and at various stress levels. The creep-rupture lifetime of the processed material was similar to the base metal. Detailed electron microscopy analysis of the failed sample was carried out to understand the microstructural evolution in various locations of the sample during creep.

creep↗
DOE OSTI2021

AC losses of Roebel and CORC ® cables at higher AC magnetic fields and ramp rates

We have measured ReBCO coated conductor-based conductor on round core (CORC ® ) and Roebel cables at 77 K in a spinning magnet calorimeter, which subjected the tapes in the samples to a radial magnetic field of 566 mT (peak) at frequencies up to 120 Hz (272 T s -1 , cyclic average) with an approximately sinusoidal waveform. The samples were oriented such that the field applied to the tapes within the cables was entirely radial, simplifying subsequent analysis. An expression for loss which included hysteretic, flux creep and eddy current losses was fit to both the CORC ® and the Roebel cables. This expression allowed easy comparison of the relative influence of eddy currents and flux creep (or power-law behavior) effects. The loss of both the CORC ® and Roebel cables measured here were seen to be essentially the sum of the hysteretic loss, flux creep effects, and the normal metal eddy current losses of the individual tapes. The losses of these cables were measured at high B × d B /d t with no coupling current loss observed under the present preparation conditions. The influence of flux creep effects on loss were not negligible. The losses of the CORC ® cable per meter of tape were seen to be reduced from the case of a flat tape because of the helical geometry of the tapes.

Physics↗
DOE OSTI2020

Report on FY 2020 Testing in Support of the Development and Extension of ASME Code Rules for Grade 91

This report summarizes the FY 2020 research and activities at Oak Ridge National Laboratory in support of the ASME code rule development and code extension for Grade 91 (Gr. 91) steel. Incorporation of the Gr. 91 temperature-dependent fatigue curves in Section III Division 5 was one major task, and the associated major aspects brought up during the course of the ASME balloting process are documented in this report. Experiments and analysis continued on the development of the alternative creep-fatigue evaluation based on elastic–perfectly plastic (EPP) plus simplified model test (SMT) methodology. The focus of the study in FY 2020 was the evaluation of the hold-time effect at high cycle and low strain range region. Baseline testing in support of the evaluation of hold time effects was started and will continue in FY 2021. Major on-going experiments and activities in support of the ASME code development and extension of Gr. 91 will be completed in FY 2021.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2023

Relationship between Grain Size and Sample Thickness on the Creep-Rupture Performance of Thin Metallic Sheets of INCONEL Alloy 740H

A study was conducted on INCONEL® alloy 740H® to examine the role of grain size and sheet thickness on the alloy’s creep-rupture behavior. Three different starting sheet thicknesses were utilized and multiple heat-treatment conditions anticipated for compact heat exchanger (CHX) manufacturing were applied to produce a range of grain sizes. Creep-rupture testing was conducted at 750 °C for times up to about 6000 h and the results were compared to wrought databases. The data show that both creep strength and ductility were important factors in the overall creep performance of the sheets. Reductions in performance were observed due either to accelerated creep when grain size was fine or loss of rupture ductility when grain sizes approached the sheet thickness. Some combinations of heat-treatment and thickness were able to produce typical expected wrought creep properties. Historically a ‘rule-of-thumb’ requirement for creep testing suggests 3-5 grains per sample minimum dimension to ensure homogeneous behavior. This research shows that to ensure representative wrought creep performance (i.e. no effect of sample size), the sample minimum cross-section should be 10 times the average ASTM grain size. Statistical analysis of the microstructures suggests the population of larger grains as a controlling feature in creep failure.

14 SOLAR ENERGY↗
DOE OSTI2020

Preliminary description of a new creep-fatigue design method that reduces over conservatism and simplifies the high temperature design process

The report provides the initial description of a new creep-fatigue design method for structural components in high temperature nuclear service. The new method is based on an integrated elastic-perfectly plastic (EPP) analysis and Simplified Model Test (SMT) approach that reduces over conservatism, improves the treatment of elastic follow up, and simplifies the design procedure, when compared with the current creep-fatigue design methods in ASME Boiler and Pressure Vessel Code. Developing the design charts for the EPP-SMT design method requires extrapolating SMT test data as a function of hold time and follow up factor. The report develops the preliminary design charts for Alloy 617 at temperatures between 800°C and 950°C by combining two extrapolation approaches developed in a previous work. The report also presents a comparative analysis between the EPP-SMT design method and the current ASME creep-fatigue design methods by evaluating design life of two sample geometries under different loading conditions. Results from the comparative analysis verify the EPP-SMT design charts but suggest the requirement of additional test data in the low strain range regime for improving the extrapolation procedure that will further reduce the over conservatism in the creep-fatigue damage evaluation. The report also concludes that the EPP-SMT design procedure can account for effect of primary load on creep-fatigue life by using a fixed, bounding value of follow up in constructing the design charts. The conclusions to this report describe the future work required to complete this new design method so it can be codified through a nuclear Code Case.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Initial Development of Variable Design Lifetimes and Creep-Fatigue Evaluations for ASME Section III, Division 5, Class B Code Rules

This report summarizes the initial development of new ASME Section III, Division 5, Class B rules to address the gaps identified for new high temperature reactor designs. The overall objective is to introduce the design-by-analysis approach, the variable design lifetimes for primary load design, and the strain limits and creep-fatigue damage evaluations for Class B components. It is also desired that the new evaluation procedures do not require stress classification and stress linearization. Further, the data requirements to support the development of design parameters for the new Class B rules would not be overly burdensome, and less extensive than those supporting Class A rules. We have identified the Elastic, Perfectly Plastic (EPP) method as the design by-analysis approach for primary load design, and developed allowable stress criteria for variable design lifetimes, up to 500,000 hours, that only require data typical for the allowable stresses in Section II, Part D, Tables 1A and 1B. We have also adapted the elastic analysis approach from HBB-T-1400 and Section III, Mandatory Appendix XIII, XIII-2400 and XIII-3520(e) for the new Class B creep-fatigue evaluation procedure. A new elastic follow-up-based Isochronous Stress Strain Curve (ISSC) stress relaxation procedure has been developed to provide adequate conservatism commensurate with Class B constructions. No stress classification and stress linearization are required in the new procedure. Future work needed to complete the development is also summarized.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Data-Driven Surrogate Modeling with Microstructure-Sensitivity of Viscoplastic Creep in Grade 91 Steel

Abstract To support the development of advanced steel alloys tailored to withstand extreme conditions, it is imperative to account for the mechanical performance of components, while considering the influence of local microstructure on the macroscopic response. To this end, this study focuses on the development of microstructure-sensitive constitutive models for the mechanical response of Grade 91 steel exposed to extreme thermo-mechanical environments. Polynomial chaos expansion (PCE) surrogates are used to emulate high-fidelity polycrystal simulations of the viscoplastic response of Grade 91 steel as a function of the microstructure fingerprint (e.g., dislocations and precipitates). To cover a wide temperature–stress domain, two separate PCE surrogates—one that captures softening and the other that captures hardening behavior—are combined using another (sparse) Gaussian process regression model. The resulting constitutive creep surrogate model is integrated within the MOOSE finite element framework to simulate the intricate effects of microstructure, in particular MX-phase precipitates, on a component with a graded microstructure. Surrogate sensitivity analysis is applied to quantify the relevant impact of spatially varying microstructure on the creep response in a test-case involving a Grade 91 alloy with a prototypical weld.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Temporal and Spatial Evolution of Non-Elastic Strain Accumulation in Stanstead Granite During Brittle Creep

Understanding the long-term behavior of brittle rocks requires fundamental consideration of time-dependent strain evolution and brittle creep processes. Previous studies have evaluated sub-critical crack growth during time-dependent deformation and damage evolution in brittle rocks; however, there is an incomplete knowledge of how damage evolves spatially and temporally within the body of intact rocks, where distributed regions of damage interact and coalesce during creep. This paper presents laboratory research focusing on evaluating brittle creep damage processes in Stanstead granite (SG) using 2-dimensional digital image correlation (2D-DIC). In the laboratory, the prismatic SG specimens were loaded beyond an estimated Crack Damage stress threshold (CD) level and then maintained a constant stress to initiate the creep process. DIC was used to characterize full-field spatiotemporal strain evolution, which was then interpreted in the context of local regions of “damage”, determined according to a strain-based criterion. Here, a method was proposed for identifying “existing” and “new” damage regions over specified intervals during the test, followed by spatial clustering of these regions to assess their spatiotemporal evolution. The clustering analysis results demonstrated the extension of existing damage regions was the main damage process during brittle creep, which is consistent with existing models of sub-critical crack growth. In addition, temporal analysis of tensile and shear strains on a point-by-point basis revealed both new damage formation and the strain concentration within existing damaged regions significantly contribute to overall specimen strain during primary creep. In contrast, during secondary creep, increases in specimen deformation are influenced by the accumulation of strains within already damaged regions.

58 GEOSCIENCES↗
DOE OSTI2021

Characteristics of Premature Creep Failure in Over-tempered Base Metal of Grade 91 Steel Weldment

Characteristics of premature creep failure in the over-tempered base metal (OT-BM) of a Grade 91 steel weldment are investigated with specially designed creep experiments and advanced microstructure characterization. In situ digital image correlation (DIC) strain measurements reveal that local creep strain as high as 100% accumulated in the OT-BM, compared with only 10% nominal strain over the gauge length. The creep strain rate in the OT-BM is identical to that in the intercritical heat-affected zone and fine-grained heat-affected zone at the secondary creep stage and early tertiary stage, but faster at the late tertiary stage. Microstructural analysis shows that highly recovered microstructure in the OT-BM leads to the lowest hardness, the largest grain size, the lowest fraction of coincidence site lattice boundaries, and the lowest localized strain energy. Dislocation creep and transgranular creep fracture are the dominant deformation and fracture mechanisms in the OT-BM under the current creep testing condition of a low temperature (550 °C) and a high stress (215 MPa).

42 ENGINEERING↗
DOE OSTI2024

Wrought FeCrAl alloy (C26M) cladding behavior and burst under simulated loss-of-coolant accident conditions

Cladding burst experiments for FeCrAl cladding were performed in the Severe Accident Test Station facility at Oak Ridge National Laboratory. These experiments were simulated using the BISON fuel performance code to better understand the cladding plastic behavior and failure under simulated loss-of-coolant accident conditions. 3D cladding surface boundary conditions were generated using composite axial and azimuthal profiles from experiment thermocouple data. To improve the simulation analysis capabilities in BISON for cladding burst behavior, new thermal creep, plasticity, and failure stress models specific to C26M, a wrought FeCrAl alloy, were developed and implemented. Initial cladding burst results indicated a general underprediction in the failure temperature of the six cladding burst simulations versus the observed failure temperatures. Close investigation of the experiment timing versus the underlying tensile test data revealed that, compared with the tensile specimens, the cladding tubes did not experience the same long holding time at high temperatures. New tensile tests were performed at high temperatures using a temperature ramp similar to the simulated loss-of-coolant accident experiments. These new tensile curves showed an approximately 80% increase in the ultimate tensile strength of the C26M alloy, indicating that a holding time of 10 min at 700 °C and 800 °C allows annealing to change the material microstructure. Using the updated tensile properties, the burst temperatures and stresses from the simulations showed remarkable agreement with the experimental results. This study was then extended by varying the initial pressure to highlight the burst temperature difference between standard Zircaloy-4 and C26M cladding under equivalent conditions. The results show that C26M has a burst temperature that is approximately 70–130 K greater than that of Zircaloy-4. In conclusion, these modeling predictions can be further improved by collecting high-temperature tensile data for C26M beyond the temperature ranges used in this work.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Preliminary Feasibility of Printing, Microstructure Analysis and Mechanical Performance of a Down Selected Ni Alloy

This report is submitted as completion of a Milestone 3 deliverable under work package ORNL CT-23OR1304051 in support of the Advanced Materials and Manufacturing Technologies (AMMT) program. The AMMT program is aiming at the faster incorporation of new materials and manufacturing technologies into complex nuclear-related systems. An integrated approach, combining advanced characterization, high-throughput and accelerated testing, modeling and simulation including machine learning and artificial intelligence will be employed. While 316H (Fe-16-18Cr-10-14Ni-2-3Mo-0.04-0.1C) has been identified as a key alloy to be integrated into the AMMT accelerated alloy qualification approach due its relevance for many current and future nuclear energy reactors, many other alloys could be considered for the advanced fabrication of innovate high-performance nuclear components. ANL, INL, ORNL and PNNL are collaborating on identifying the most promising alloy candidates relevant for the AMMT program. A selection criteria matrix was established to evaluate the alloys considering their relative importance and technological readiness levels for nuclear energy applications, with a focus on laser powder bed fusion (LPBF). Due to the broad range of potential candidate alloys, ORNL and INL focused on Ni-based alloys, while ANL and PNNL mainly evaluated Fe-based alloys. PNNL previously published materials scorecards reports on several key alloys and this report is providing a broader overview of Ni-based candidate alloys, expending beyond alloys well-known to the nuclear community. Of particular interest are alloys that are currently commercially available in powder form due to the growing demand from other industries that have invested heavily in additive manufacturing. Among these alloys, Haynes 282 (Fe-20Cr-20Co-8Mo) was selected due to its superior strength at high temperature compared to the code-qualified alloy 617 (Ni-20-24Cr-10-15Co-8-10Mo). To assess the integration of this new alloy into the AMMT digital manufacturing framework, we performed the rapid optimization of alloy 282 printing parameters on a Renishaw 250 machine, the fabrication of sufficient materials for extensive characterization and mechanical testing both at ORNL and INL, and added the printing data into the digital platform via the Peregrine software. A detailed analysis of the LPBF 718 alloy was also conducted, with creep specimens being tested at 600-650°C and characterized by advanced electron microscopy. The alloy superior mechanical strength and great printability associated with the extensive database that has already been generated highlight the promising potential of LPBF 718 as a candidate alloy for the AMMT program. INL, ANL and PNNL have generated similar reports and all the information will be compiled into a final M2 milestone report to provide the AMMT leadership team with clear recommendations on the down selection of reactor materials, as well as establish a roadmap for the qualification of these selected alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Draft Rules for Alloy 617 Creep-Fatigue Design Using an EPP+SMT Approach

The report describes an improved new creep-fatigue design method for structural components in high temperature nuclear service. The new method uses an integrated elastic-perfectly plastic (EPP) analysis and Simplified Model Test (SMT) approach that greatly simplifies the design process by avoiding the separate evaluation of creep and fatigue damages and eliminating the requirement of stress classification. The report includes draft design rules, presented in a format compatible with an ASME nuclear Code Case, as well as a commentary on the rules and the validation of the rules using pressurized SMT (p-SMT) test data. Areas of potential improvement have been identified for further evaluation. The report also develops EPP+SMT design charts for Alloy 617 at temperatures between 800°C and 950°C by extrapolating high strain range, short hold test data to low strain range and long hold times, typical for structural components in high temperature nuclear service. The design charts are currently limited to 10,000 cycles to avoid excessive extrapolation outside the test database. More robust alternate extrapolation procedures will be considered in future work. The report includes several verification problems comparing the new EPP+SMT design method with current ASME creep-fatigue design methods. The comparison demonstrates that the EPP+SMT method significantly reduces the over-conservatism in current methods. Finally, the report includes a fully-documented sample problem with multiple load cases detailing the application of proposed EPP+SMT design rules.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Designing Cladded Components for High Temperature Nuclear Service: Part I—Analysis Methods

Use of corrosion-resistant cladding can greatly extend the design life of structural components in many advanced reactor systems. However, there are currently no ASME design rules for cladded components to guard against creep-fatigue failure and ratcheting strain accumulation in elevated temperature nuclear service. This paper, presented in two parts, addresses this gap by proposing a design strategy for cladded components that do not require long-term testing of clad materials. The proposed approach relies on approximate design analysis methods for two types of clad materials—a soft clad that creeps much faster than and has lower yield stress than the class A base material and a hard clad that creeps much slower than and has higher yield stress than the class A base material. Part I discusses the approximate analysis strategies for the clad materials—treat a soft clad as perfectly compliant and a hard clad as linear elastic—and Part II develops a complete set of design rules for each of the two types of cladded components. In conclusion, finite element analyses of representative high temperature reactor components show that the proposed design analysis methods can bound the design quantities in soft cladded components and approximate the design quantities in hard cladded components.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Reference constitutive model for Alloy 617 and 316H stainless steel for use with the ASME Division 5 design by inelastic analysis rules

This report describes the development, calibration, and validation of an inelastic constitutive model describing the monotonic, cyclic, and creep behavior of Alloy 617 from room temperature to 983 °C . The model is intended for incorporation into a new Nonmandatory Appendix to Section III, Division 5, Subsection HB, Subpart B of the ASME Boiler & Pressure Vessel Code providing guidance on developing models for use with the ASME design by inelastic analysis provisions as well as a listing of acceptable material models for each Class A material that designers can use without further validation. The report described the development of the A617 model as well as providing an updated draft appendix, ready for ASME ballot, incorporating the A617 and and the previously-developed 316H model. The development of this appendix and the related material models will promote the widespread application of the generally more efficient inelastic analysis rules rules.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

srlife : A software tool for estimating the life of high temperature concentrating solar receivers. Part II – Ceramic receivers

As Concentrating Solar Power (CSP) technologies aim for higher operating temperatures to enhance efficiency and meet industrial process heat demands, high-temperature metallic materials, including nickel-based superalloys, face challenges in maintaining structural integrity. Advanced ceramics offer a promising alternative due to their superior high-temperature strength. However, accurately assessing the performance of ceramic components requires a fundamentally different approach from that used for metallic components. This Part II of a two-part paper describes the integration of ceramic statistical failure models within srlife – an open-source tool for predicting the life of high-temperature CSP receivers. These models account for the inherent variability in ceramic strength, as well as the effects of subcritical crack growth (SCG) under high temperature cyclic loads. Here, the paper includes an example problem that demonstrate the process of evaluating ceramic receivers using srlife. Part I details the life estimation process for metallic receivers (i.e. creep-fatigue life) along with input and output data structure, thermohydraulic analysis, and structural analysis. The complete tool is available as open-source software at https://github.com/srlife-project/srlife and can be installed via the PyPi package manager (https://pypi.org). By supporting both ceramic and metallic receiver analyses, srlife facilitates fair comparisons between competing metallic and ceramic designs, enabling accurate evaluations of plant efficiency and the economic benefits of ceramic solar receivers and other components.

High temperature ceramic receivers↗
DOE OSTI2020

AGC 3 Irradiated Material Properties Analysis

This report documents the analysis of the irradiated material property data from the Advanced Graphite Creep (AGC)-3 graphite specimens. This is the third in a series of six irradiation test trains planned as part of the AGC experiment to fully characterize the neutron irradiation effects and radiation creep behavior of current nuclear graphite grades. The AGC-3 capsule was irradiated in the Idaho National Laboratory Advanced Test Reactor at a nominal temperature of 800°C, beginning with irradiation Cycle 152B on November 28, 2012 and ending with Cycle 155B on April 12, 2014, with a total received dose range of 0.9–3.7 dpa. Larger creep and control specimens located more centrally in the capsule received a dose of 1.0 – 3.7 dpa. AGC-3 was designed to provide irradiation conditions similar to AGC-1 and AGC-2 capsules (similar graphite grades tested, specimen dimensions, mechanical loading conditions) but at a different nominal irradiation temperature of 800°C. AGC-3 was irradiated for a short duration to provide material property values at lower dose levels. AGC-4 will have a longer duration and provide material property values at higher dose levels. After irradiation, material property and dimensional strain measurements were conducted on all AGC-3 specimens (from 11 nuclear graphite grades) using the same equipment and approved standards as were conducted before irradiation. The specimen loading configuration for all graphite grades within AGC-3 followed a similar pattern as earlier AGC capsules to provide easy future comparison of all irradiated material property data.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗