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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 919 records · Page 51
All sourcesNASA NTRSDOE OSTI
DOE OSTI2017

A crystal plasticity model incorporating the effects of precipitates in superalloys: Application to tensile, compressive, and cyclic deformation of Inconel 718

An elasto-plastic polycrystal plasticity model is developed and applied to an Inconel 718 (IN718) superalloy that was produced by additive manufacturing (AM). The model takes into account the contributions of solid solution, precipitates shearing, and grain size and shape effects into the initial slip resistance. Non-Schmid effects and backstress are also included in the crystal plasticity model for activating slip. The hardening law for the critical resolved shear stress is based on the evolution of dislocation density. In using the same set of material and physical parameters, the model is compared against a suite of compression, tension, and large-strain cyclic mechanical test data applied in different AM build directions. We demonstrate that the model is capable of predicting the particularities of both monotonic and cyclic deformation to large strains of the alloy, including decreasing hardening rate during monotonic loading, the non-linear unloading upon the load reversal, the Bauschinger effect, the hardening rate change during loading in the reverse direction as well as plastic anisotropy and the concomitant microstructure evolution. It is anticipated that the general model developed here can be applied to other multiphase alloys containing precipitates.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Effect of thermal aging and irradiation on microstructure and crack growth response of Alloy 690

Nickel-base Alloy 690 and the associated weld Alloys 52 and 152 are typically used for nozzle penetrations in replacement heads for pressurized water reactor (PWR) vessels, because of their excellent overall resistance to general corrosion and environmental degradation, primarily stress corrosion cracking (SCC). However, many of the existing PWRs reactors are expected to operate for 40-80 years. Likewise, advanced water-cooled small modular reactors (SMRs) will use Ni-Cr alloys and are expected to receive initial operating licenses for 60 years. Hence, the thermal stability of Ni-Cr alloys is a potential concern for the long-term performance of both existing and advanced nuclear plants, and possibly spent fuel storage containers. The objective of this research is to understand the microstructural changes occurring in high-Cr, Ni-based Alloy 690 during long time exposure to the reactor operating temperatures, and the effect of these changes on the service performance. One area of particular concern is the potential for long range ordering (LRO), i.e. formation of the intermetallic Ni 2 Cr phase under prolonged exposure to reactor temperatures and/or irradiation, which can increase strength, decrease ductility, and cause dimensional changes or lead to in-service embrittlement of components made with these alloys. Hence, this research focused on the microstructural evolution and the SCC response of Alloy 690 under accelerated thermal aging and irradiation conditions. The materials studied involved Alloy 690 from two sources: (i) Alloy 690 plate from an Alloy 152 dissimilar metal weld (DMW) joining the Alloy 690 plate to Alloy 533 LAS, aged at three different temperatures (370°C, 400°C and 450°C) for up to 75,000h (equivalent to 60 years of service), and (ii) specimens neutron-irradiated in the BOR-60 reactor up to 40 dpa. For aged Alloy 690 specimens, hardness was found to increase with aging time, however, the microstructural characterization by means of synchrotron X-ray did not find evidence of LRO. The microstructural characterization of neutron-irradiated specimens by TEM found no evidence of LRO either. Testing in a primary water environment of Alloy 690 specimens aged to a 60-year service equivalent revealed a fatigue and corrosion fatigue crack growth responses similar to those measured on the un-aged alloy. The SCC CGR response was also low. Overall, the two Alloy 690 heats investigated in this work, aged up to 60-year service equivalents or exposed to neutron irradiation up to 40 dpa, did not exhibit a deterioration in microstructure or performance.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2019

Laser Weldability of AlSi{sub 10}Mg Alloy Produced by Selective Laser Melting: Microstructure and Mechanical Behavior

Selective laser melting (SLM) allows 3D complex parts to be produced with integrated functionalities but does not permit to realize large dimension parts, as the building chamber volume of commercial SLM systems is limited. Therefore, the possibility of joining SLM-built parts by welding appears as extremely valuable. In this work, laser weldability of SLMed AlSi{sub 10}Mg parts has been investigated. The cooling rates induced by the welding process are lower than the ones of SLM; therefore, typical eutectic silicon network of SLM-built parts appears broken in both the melted zone and part of the heat-affected zone, as confirmed by calorimetric measurement. This microstructural evolution caused a local decrease of hardness from 132 HV to 73 HV and a reduction of ductility caused by porosity formation in the weld bead. Moreover, the thermal treatment, performed at 320°C, can limit the gap of tensile response among welded bead and base SLM material.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Effect of Heat Treatment and Combination of Cold Rolling and Heat Treatment on Microstructure and Mechanical Properties of Titanium Alloy Ti6Al2V2Zr1.5Mo

The heat treatment and cold rolling combinations have been carried out on titanium alloy Ti6Al2V2Zr1.5Mo, and microstructure evolution and mechanical behavior have been studied. Solution treatment below the β-transus temperature, followed by air cooling, resulted in higher microhardness/strength as compared to the same with water quenching. A sudden drop in microhardness/strength is observed in sample solution heat-treated above β-transus temperature followed by air cooling. The former is attributed to the additional presence of fine secondary α-phase formed by dynamic aging during air cooling as compared to water-quenched samples which did not have fine secondary α-phase. Solution treatment above β-transus temperature resulted in Widmanstatten microstructure with no significant fine secondary α in air-cooled samples. Among the studied conditions of cold rolling (CR), gain in strength of the alloy from annealed condition is significant with first 15% reduction and thereafter it is marginal for 30% reduction. Initiation of cracks at the edges has been observed in 30% CR. The microstructure of cold-rolled samples confirms the fragmentation of α-plates with the presence of high dislocation density. Heat treatment of cold-rolled samples resulted in significant reduction in strength from the as-cold-rolled conditions. The marginally lower strength than the as-received (annealed) or heat-treated alloy samples is due to the recrystallization in CR samples and the formation of Widmanstatten microstructure in air-cooled samples. The alloy does not have fine secondary α or regions with large dislocation density in this condition. The microstructure in the samples heat-treated (with air cooling) below as well as above β-transus temperature (after CR) is similar to air-cooled samples (without prior CR) with heat treatment above β-transus temperature. This indicates the reduction in recrystallization temperature with cold working, which is substantiated with the reduction in strength as well.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Testing fast reactor fuels in a thermal reactor: Comparison of transmutation metallic fuel alloys behavior by scanning electron microscopy

To optimize nuclear waste repository performance, the destruction of minor actinide elements, particularly Np and Am, in a neutron fast spectrum reactor is possible by incorporating these elements into nuclear fuel. Evaluating the performance of minor actinide containing fuel is of paramount importance to enabling this technology. However, such a task is challenging without an available domestic fast spectrum test reactor. A comparison of fuel performance tested in an available domestic thermal reactor at the Idaho National Laboratory, the Advanced Test Reactor, and in a fast spectrum reactor in France (Phénix) is presented here in this study. This study evaluates the capability of using a cadmium shrouded test position to mimic the power profile along the fuel radius present in fast spectrum reactors so that thermally driven phenomenon (e.g., constituent redistribution) can be evaluated in a thermal reactor and determined to be prototypical of a fast reactor. Thus, optical microscopy and scanning electron microscopy has been performed on irradiated 35U-29Pu-4Am-2Np-30Zr fuel samples (where the number preceding the element is the weight percent concentration) from the two mentioned reactors that present similar irradiation temperatures and power conditions. The results indicate that fuel performance phenomena are reproducible in the two irradiation conditions. The redistribution of Zr occurred in the same manner for the two samples. Similar partitioning of U-Pu-Zr phases was observed, and the behavior of Am was similar in the analyzed specimens. Finally, the overall microstructure evolution seems not to be affected by minor actinides addition compared to expected behavior of conventional U-19Pu-10Zr ternary metal fuels for both specimens. Slight differences in fuel cladding chemical interaction were, however, observed. This difference is likely driven by difference in cladding composition rather than irradiation conditions.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2019

Progress on Grizzly Development for Reactor Pressure Vessels and Reinforced Concrete Structures

The Grizzly code has been under development for the U.S. Department of Energy’s Light Water Reactor Sustainability program to provide predictive tools for the evolution of material degradation in critical light water reactor structural components due to long-term exposure to the environmental conditions of normal reactor operation, and for the effects of this degradation on the safety of these components. This development has primarily targeted reactor pressure vessels and reinforced concrete structures. Work performed during Fiscal Year 2019 added important features for both of these types of structures. For probabilistic fracture mechanics analysis of reactor pressure vessels, capabilities were added to account for the effects of warm prestressing and residual stresses, as well as to model crack initiation, growth, and arrest. For modeling microstructure evolution in reactor pressure vessels, a cluster dynamics model for evolution of Mn-Ni-Si phases has been implemented. For modeling degraded reinforced concrete structures, capabilities to consider the combined effects of damage and creep in the concrete constitutive model and model nonlinear behavior of reinforcing bars has been added. These newly-developed features fill important gaps in Grizzly’s feature set for engineering-scale analysis of degraded reactor pressure vessels and reinforced concrete structures. Grizzly development in both of these areas has reached a point where it is ready for extensive testing on relevant engineering problems.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Microstructural, Oxidation, and Mechanical Behavior of NbTi-Based Refractory Alloys with 5 to 10 Pct Co, Cr, and Ni Additions

NbTi-based refractory alloys with additions of Co, Cr, and Ni represent an interesting medium-entropy alloy system with potential for protective oxide film formation, high strength, and ductility. This study investigates the microstructural evolution, oxidation behavior, and mechanical properties of NbTi-based alloys containing 5 to 10 at. pct Co, Cr, and Ni. CALPHAD predictions suggest that this composition range can be heat treated to obtain a predominantly body-centered cubic matrix phase. Mechanical properties, including microhardness, yield strength, maximum strength, and specific strength are evaluated through isothermal compression tests conducted between room temperature and 800 °C. The oxidation kinetics of these alloys are assessed through discontinuous oxidation tests. Parabolic oxidation kinetics were observed for NbTi–10Ni and NbTi–5Co, while linear oxidation kinetics were found for NbTi–10Cr and NbTi–10(CoCrNi). Microstructures and oxide layers are characterized using X-ray diffraction, electron backscatter diffraction, energy-dispersive X-ray spectroscopy, and scanning electron microscopy. All alloys exhibit significant mechanical softening between room temperature and 800 °C, with elastic-perfectly plastic flow observed at 800 °C. The addition of 10 pct Cr to NbTi resulted in two BCC phases up to 1050 °C, conflicting with CALPHAD predictions of a single-phase solid solution at this temperature, and resulting in higher flow stress at 800 °C. NbTi–10(CoCrNi) exhibited the lowest flow stress at 800 °C despite having more ‘cocktail effect’ potential and insufficient molar fractions of Co, Cr, or Ni to form a desirable protective oxide film.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Corrosion Response of Ni-19Cr-5Fe in Molten NaCl-MgCl 2 Salt

Ni-based alloys are strong candidates for use in high-temperature molten salt reactors due to their superior corrosion resistance and mechanical stability compared to stainless steels. In this study, the static corrosion behavior of a Ni-19Cr-5Fe model alloy was systematically evaluated in a purified molten NaCl-MgCl 2 salt at 700°C for 30, 240, and 500 h. Post-exposure analyses were conducted to assess microstructural evolution, corrosion depth, and elemental depletion profiles. Corrosion rates, quantified by chromium depletion depth, followed an inverse power-law trend with increasing exposure time, indicating diffusion-limited kinetics. This trend is attributed to limitations in mass transport in the static salt and to the progressive local depletion of reactive chromium species. Coupled electron backscatter diffraction and energy dispersive X-ray spectroscopy analysis further revealed that the grain boundary character significantly influences corrosion susceptibility: high-angle grain boundaries exhibited pronounced Cr depletion and pitting, while low-angle and Σ3 boundaries remained comparatively resistant. These results offer valuable insight into the role of microstructure in corrosion processes and reinforce the importance of time-dependent material evaluation in molten salt environments relevant to advanced reactor designs.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

An Integrated High-Speed Microstructural Characterization Method Using Simultaneous XRD, Stereo-DIC, and PCI

High-speed characterization of the deformation mechanisms in polycrystalline metals requires the quantification of full strain fields and local microstructural evolutions simultaneously. In this paper, we present a novel experimental method to integrate phase-contrast imaging (PCI), stereographic digital image correlation (stereo-DIC), and full-ring X-ray diffraction (XRD) to allow for the simultaneous characterization of polycrystalline metals at 1MHz or higher. A Kolsky bar was integrated into the synchrotron X-ray source in Sector 32 ID-B at the Advance Photon Source (APS) at Argonne National Laboratory. When the sample is dynamically loaded, the diagnostic methods of full-ring XRD, PCI, and stereo-DIC are properly synchronized to record the deformation behavior at both continuum and microstructural scales as a function of the loading history. An advanced high-strength steel (AHSS) is used as a model material to demonstrate the capabilities of this new experimental method.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Deep operator network surrogate for phase-field modeling of metal grain growth during solidification

A deep operator network (DeepONet) has been constructed that generates accurate representations of phase-field model simulations for evolving two dimensional metal grain morphology growing from melt. These representations serve as lower resolution, computationally efficient stand-ins for quick parameter space exploration of solutions to the the Allen-Cahn equations that dictate the phase-field model simulations. The experimental target for the phase-field model is a uranium casting system cooling a 434 g uranium charge from a maximum temperature of 1400° C at an average rate of 30° C / min , traversing the crystallographic phases of the pure metal. Experimental parameters inform the phase-field model, whose higher resolution computational model solutions are used to train the DeepONet in a given parameter space with the aim of developing a faster, more efficient method for predicting the solidifying metal's microstructure at different potential experimental values. The final DeepONet generates high accuracy, lower resolution predictions with cumulative relative approximation error over all timesteps of less than 0.5%, while ensuring solutions remain within physically feasible ranges. Further, these relative error values are comparable with other state-of-the-art DeepONet models for microstructure evolution, while significantly reducing the amount of training data required. Training a convolutional neural network simultaneously with the DeepONet, enforcing realistic values at the complex metal grain boundaries, and mathematically encoding boundary conditions into the structure of the DeepONet improved prediction accuracy and computational efficiency over a standard DeepONet model.

36 MATERIALS SCIENCE↗
DOE OSTI2017

The characterization of microstructure and chemistry of transmutation fuels

The goal of the fast reactor development programs is fabrication and certification of a nuclear fuel system that performs all functions of a conventional fuel while destroying recycled actinides. Metal fuels, such as U-Pu-Zr fuels, are considered to be candidates for this application. The physical and mechanical properties, as well as behavior laws and correlations of metal alloy fuel, all of which define the behavior and performance of metal alloy fuels has been investigated in detail. The results indicated that the prospect for fueling a future fast spectrum reactor using metal fuels is excellent. There are several challenges associated with the fuel implementation in reactor environment. One of the limiting factors in lifetime and safety of thermal and fast reactor systems is fuel swelling and resulting fission product transport to cladding. Understanding diffusion kinetics and phases formed between metal fuel and cladding upon exposure to high temperatures typical in reactor environment is critical for ensuring integrity, safety, and performance of the material, advancement of this type of fuel in the future, and securing long-term success of the nuclear fleet. The first step to understanding fuel-cladding interaction is investigation of an as-cast fuel microstructure. Despite the importance of these fuels, detailed description of microstructures in these materials is extremely limited. The majority of published results are based on characterization of as-cast microstructures of these fuels in scanning electron microscopes (SEM). In this work, we present the results from microstructural characterization of metallic Pu-based fuels, which is essential in the validation of current and future atomistic and meso-scale modeling efforts. A firm understanding of microstructural evolution in reactor materials is imperative and will lead to deeper understanding of in-reactor degradation behavior, creating a new generation of radiation-resistant materials and fuels with the potential for significant increases in burn-up.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Evolution of the structure and chemical composition of the interface between multi-component silicate glasses and yttria-stabilized zirconia after 40,000 h exposure in air at 800 °C

The chemical and structural stability of two commercial multicomponent silicate glasses (SCN and G6) in contact with yttria-stabilized zirconia (YSZ) was investigated after exposure times of up to 40,000 h in air at 800 °C. With exposure time, interfacial layers develop at the SCN-YSZ and G6-YSZ interfaces, which were characterized in detail using both quantitative chemical analysis and atomic-resolution imaging. At the SCN-YSZ interface, a Ca-Ba-Si-O reaction phase was found to grow by diffusion control. In G6-YSZ, Raman spectroscopy and electron microscopy revealed a disorganized interfacial reaction later between G6 and YSZ, and the occurrence of cubic to tetragonal to monoclinic phase transformations in YSZ. Finally, this microstructural evolution is discussed in terms of devitrification resistance of glass and diffusion processes at interfaces.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Sintering and characterization of SrBi{sub 2}Ta{sub 2}O{sub 9} obtained by high-pressure processing at low temperatures

High-pressure processing is a very attractive approach for the production of materials with new and/or improved properties. In this work, pressures in the order of 7.7 GPa and 2.5 GPa were induced in SrBi{sub 2}Ta{sub 2}O{sub 9} samples at different temperatures placed in a specific reaction cell and generated different effects on phase formation. The microstructural evolution during high-pressure processing was investigated by scanning electron microscopy in association with energy dispersion spectroscopy and with the support of an X-ray diffraction analyzer. Frequency response analysis was used to obtain the dielectric curves by electrochemical impedance spectroscopy. A SrBi{sub 2}Ta{sub 2}O{sub 9} single-phase sample, treated at 2.5 GPa and 900 °C, was used to evaluate the electrical properties, obtaining a dielectric response similar to SrBi{sub 2}Ta{sub 2}O{sub 9} samples sintered by conventional processes at temperatures above 1000 °C. In addition, by this method, it was possible to obtain ceramics with uniform microstructure and a relative density of 93%. - Highlights: • The first production of SrBi{sub 2}Ta{sub 2}O{sub 9} using the technique of high-pressure processing. • The ability to produce single-phase SrBi{sub 2}Ta{sub 2}O{sub 9} treated at 2.5 GPa and 900 °C. • The electrical properties are compatible with SBT sintered at high temperatures.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Modeling of flash sintering of ionic ceramics

A fundamental understanding of the influence of defects in ionic ceramics at the atomic, microstructural, and macroscopic levels, before, during, and after the flash sintering event is key to the development of ceramic processing operations that lead to fast, low cost, and environmentally safe fabrication of materials. The observed phenomenology of the flash process encompasses multiple time and length scales and have resulted on a wide variety of what sometimes appears to be contradictory explanations. Here, this article summarizes the latest developments on the modeling and simulation of flash sintering, specifically those related to the understanding of the equilibrium and kinetic properties and the corresponding microstructural evolution of ionic ceramics. Challenges and opportunities in the development of theoretical analyses that include unidentified multiphysical effects are discussed, as they pertain to the processing of technologically relevant ceramic materials for advanced structures and devices.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Grain Structure Evolution in Fe-6Si During Directed Energy Deposition

The purpose of this study is to explore the effect of additive manufacturing (AM) process variables on the grain structure of Fe-6Si, a soft-magnetic alloy used in electrical machine and grid applications. Samples were fabricated with laser engineered net shaping (LENS) with varying inter-pass timing and numbers of unidirectional passes. Here the results show that the grain structure was affected by both solidification and solid-state grain growth mechanisms. A model of the LENS process suggests that, although shorter inter-pass times encourage greater nucleation of new grains and therefore grain refinement during solidification, these conditions also help maintain high solid-state temperatures that allow for grain boundary motion to keep pace with the build rate. Grains formed under these conditions may span multiple layers, and the high-temperature gradient promotes directional growth. This new understanding of these microstructure evolution mechanisms will aid in using process conditions to control the competition between solidification and solid-state grain growth to create grain structures that may not be possible with conventional processing.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Grain boundary precipitation phenomena in an alloy 33 (Cr-Fe-Ni-N) subjected to direct-aging treatments (700 °C and 900 °C)

Highlights: • Complex GB precipitation occurs in Alloy 33 upon aging at 700 °C: conventional and DP modes. At 900 °C only the former occurs. • Two types of DP colonies were observed at 700 °C: unidirectional/parallel and multidirectional/irregular precipitates. • X-ray micro analyses reveal that irregular DP products develop more than one precipitate phase within the same DP colony. - Abstract: Precipitation behavior of alloy 33 upon isothermally aging at 700 °C and at 900 °C was studied by scanning electron microscopy (SEM), transmission electron microscopy (TEM) and X-ray energy dispersive spectroscopy (XEDS). The name, alloy 33, reflects the quasi-equal atomic content of the base elements Fe, Ni and Cr close to 33%, with the addition of Mo and N. The most remarkable features of the microstructural evolution resulting from the aging heat treatments are described as follows: aging at 700 °C leads to homogeneous and heterogeneous grain boundary precipitation, where the discontinuous mode is dominant at this temperature. Conversely, the opposite behavior was observed when the alloy is aged at 900 °C: predominantly homogeneous precipitation together with grain boundary precipitation, however with rare evidence for discontinuous precipitation (DP), even after longer aging times. In the present study, the topology and content of the DP colonies generated by the combined effect of grain boundary migration diffusion and precipitation under isothermal aging at 700 °C were particularly investigated. A variety of morphological features were observed: mainly (1) classical-type microstructure with straight and parallel lamellar precipitates with regular interlamellar spacing and (2) another microstructure with irregular and complex DP colonies. According to our analytical electron microscopy observations, the latter shows that there are more than one precipitate phase within the same colony, which is new to the current theory and experimental evidence on this subject.

36 MATERIALS SCIENCE↗
DOE OSTI2016

In-situ transmission electron microscopy growth of nanoparticles under extreme conditions

The formation and time resolved behavior of individual Pb nanoparticles embedded in silica have been studied by in-situ transmission electron microscopy observations at high temperatures (400–1100 °C) and under 200 keV electron irradiation. It is shown that under such extreme conditions, nanoparticles can migrate at long distances presenting a Brownian-like behavior and eventually coalesce. The particle migration phenomenon is discussed considering the influence of the thermal energy and the electron irradiation effects on the atomic diffusion process which is shown to control particle migration. These results and comparison with ex-situ experiments tackle the stability and the microstructure evolution of nanoparticles systems under extreme conditions. It elucidates on the effects of energetic particle irradiation-annealing treatments either as a tool or as a detrimental issue that could hamper their long-term applications in radiation-harsh environments such as in space or nuclear sectors.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Effect of friction stir welding and post-weld heat treatment on a nanostructured ferritic alloy

Nanostructured ferritic alloys (NFAs) are new generation materials for use in high temperature energy systems, such as nuclear fission or fusion reactors. However, joining these materials is a concern, as their unique microstructure is destroyed by traditional liquid-state welding methods. The microstructural evolution of a friction stir welded 14YWT NFA was investigated by atom probe tomography, before and after a post-weld heat treatment (PWHT) at 1123K. The particle size, number density, elemental composition, and morphology of the titanium-yttrium-oxygenenriched nanoclusters (NCs) in the stir and thermally-affected zones were studied and compared with the base metal. No statistical difference in the size of the NCs was observed in any of these conditions. After the PWHT, increases in the number density and the oxygen enrichment in the NCs were observed. Therefore, these new results provide additional supporting evidence that friction stir welding appears to be a viable joining technique for NFAs, as the microstructural parameters of the NCs are not strongly affected, in contrast to traditional welding techniques.

36 MATERIALS SCIENCE↗