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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 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Carbon availability, soil pH, and microbial allocation to nitrogen acquisition shape grassland heterotrophic respiration in response to a decade of nitrogen addition

Previous work has found that anthropogenic inputs of nitrogen (N) and phosphorus (P) impact heterotrophic respiration during soil organic matter decomposition in grasslands, a critical pathway through which carbon (C) is lost from soil to the atmosphere. While N addition typically reduces heterotrophic respiration, why the strength and direction of this N effect varies among sites is unclear. Here, to address this, we conducted a 339-day laboratory incubation to measure heterotrophic respiration from nine grasslands across North America that have received 10 years of factorial N and P fertilization. N addition reduced cumulative respiration most at sites with low pH, low microbial allocation towards N acquisition, and high soil C concentration and availability. However, N addition had neutral rather than positive effects on heterotrophic respiration in sites with high pH and decomposer allocation towards N acquisition. Across sites, a decade of N addition reduced heterotrophic respiration by ∼24 %, driven by reductions in microbial biomass. Heterotrophic respiration was less sensitive to P addition, despite its increasing microbial biomass. However, simultaneous N and P addition did ameliorate negative N effects. These results show that previously observed variation in the response of heterotrophic respiration to N addition can be explained by soil C availability and pH status, widely measured factors which can be used to predict how grassland C fluxes may change under continuing nutrient deposition.

N addition↗
DOE OSTI2021

A coupled fluid-mechanical workflow to simulate the directed energy deposition additive manufacturing process

Simulation of additive manufacturing processes can provide essential insight into material behavior, residual stress, and ultimately, the performance of additively manufactured parts. In this work, we describe a new simulation based workflow utilizing both solid mechanics and fluid mechanics based formulations within the finite element software package SIERRA (Sierra Solid Mechanics Team in Sierra/Solid Mechanics 4.52 User’s Guide SAND2019-2715. Technical report, Sandia National Laboratories, 2011) to enable integrated simulations of directed energy deposition (DED) additive manufacturing processes. In this methodology, a high-fidelity fluid mechanics based model of additive manufacturing is employed as the first step in a simulation workflow. This fluid model uses a level set field to track the location of the boundary between the solid material and background gas and precisely predicts temperatures and material deposition shapes from additive manufacturing process parameters. Next, the resulting deposition shape and temperature field from the fluid model are then mapped into a solid mechanics formulation to provide a more accurate surface topology for radiation and convection boundary conditions and a prescribed temperature field. Solid mechanics simulations are then conducted to predict the evolution of material stresses and microstructure within a part. By combining thermal history and deposition shape from fluid mechanics with residual stress and material property evolutions from solid mechanics, additional fidelity and precision are incorporated into additive manufacturing process simulations providing new insight into complex DED builds.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Effect of bacterial cell addition on Fe(III) reduction and soil organic matter transformation in a farmland soil

The coupled biogeochemical processes of Fe(III) reduction and organic matter transformation profoundly impact terrestrial carbon cycling. However, little is known about the microbial role in soil organic matter (SOM) transformation during Fe(III) bio-reduction. Here we investigated the bio-reduction behavior of a black farmland soil and corresponding SOM transformation under circumneutral and anoxic conditions. A model dissimilatory Fe reducing bacterium, Geobacter sulfurreducens, was added in either live or dead form in order to enhance Fe(III) reduction in soil and to evaluate the accompanying transformation of SOM. The progress of Fe reduction was monitored and SOM transformation was characterized by various spectroscopy methods. Results showed that addition of either dead or live G. sulfurreducens cells increased the Fe(III) reduction rate and extent. Without cell addition, SOM transformation was insignificant within 13 days of incubation, only with some consumption of aliphatic/protein compounds, apparently due to their higher bio-degradability. Addition of dead or live cells resulted in more drastic SOM transformation, but through different mechanisms. With dead cell amendment, cell necromass and debris stimulated the activity of indigenous soil microbes by serving as extra carbon/energy sources. During Fe(III) reduction, the aliphatic/protein compounds were preferentially consumed by indigenous microbial communities, similar to the treatment without cell addition but with a greater extent of consumption. In comparison, addition of live G. sulfurreducens cells stimulated degradation of less bioavailable compounds, including more saturated and higher molecular weight SOM. It is possible that fast depletion of labile SOM by live G. sulfurreducens cells favored utilization of less bioavailable molecules (such as those with more aromatic structures) by the originally dormant species in native microbial community, suggesting an active role of live Fe(III)-reducing bacteria in affecting SOM transformation. In addition, fast assimilation of microbial related carbon, such as aromatic proteins and microbial byproducts, into SOM pools was also observed. Overall, our results suggest that addition of Fe(III)-reducing bacteria to a native soil can enhance Fe(III) reduction and accelerate the turnover of SOM through various mechanisms. The study provides new insights into coupled Fe(III) reduction and SOM transformation, as well as the “priming effect” of SOM using microbial cells as substrate.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Probing the Effectiveness in Stabilizing Lithium Metal Anodes through Functional Additives

A variety of electrolyte additives were comprehensively evaluated to understand their relative capability in stabilizing lithium metal anode. Although the Li||Cu test is an effective test to rule out ineffective additives, a reliable assessment of individual additives cannot be obtained just by a single evaluation method. Therefore, various methods must be combined to truly assess the stabilization of a lithium anode. Moreover, it was also discovered that a significant depletion of electrolytes occurred during the end-of-life of the lithium batteries, which partially contributed to the sudden failure of the lithium batteries during cycling. However, the main culprit of the sudden failure was identified as the significant increase in the resistance of the lithium metal anode. Further, when used as an additive, cyclic fluorinated carbonates are the most effective in stabilizing the lithium anode and improving the cycling performance of lithium batteries among all the common additives. Despite its cost-effectiveness, the additive in the conventional electrolyte approach provides insufficient protection for lithium metal due to the complete consumption of the additive materials, which is necessary to repair the solid-electrolyte interphase (SEI). Therefore, it is suggested that a larger ratio (>15 wt %) of the SEI former should be employed to achieve effective lithium stabilization.

25 ENERGY STORAGE↗
DOE OSTI2022

X-ray Computed Tomography as a Metrology Technique for the Analysis of Additively Manufactured Material

X-ray computed tomography (X-ray CT) is an analytical technique used in materials science to non-destructively characterize features in a variety materials like polymer, metals, composites, and explosives. It also has the capability of imaging additively manufacture, machine and assembled parts. The non-destructive imaging allows for the analysis of features (voids and cracks), which give a fundamental understanding of the material characteristics. Additionally, X-ray CT can obtain accurate measurements of dimensional and topographic variations due to different stimuli and assess the accuracy of material production. This study focuses on parts manufactured via metal additive manufacturing (AM). Although AM produces parts faster and easier, the printing process can produce defects (pores and surface roughness) that undermine the part’s mechanical properties and performance. The analysis of 3D printed objects has an asset in that the material has an STL file from which the item was printed, which is not available in many manufactured materials (i.e., foams) due to stochastic structures. For this study, the print accuracy of four additively manufactured cylinders will be assessed via X-ray CTto approximate the surface roughness and visualize any major morphological changes to assess the dimensional accuracy of complex additively manufactured parts. It was concluded that using X-ray CT to measure surface roughness was affective because reasonable surface roughness values were measured. Additionally, itwas determined that small-scale features can be produced via additive manufacturing with strong dimensional accuracy so long as the features are highly complex with sharp grooves.

36 MATERIALS SCIENCE↗
DOE OSTI2025

SiC Receiver/Reactor by Additive Manufacturing for Concentrated Solar Thermocatalysis with Thermal Energy Storage (Final Technical Report - Public)

The direct use of solar thermal energy provides opportunities for low-cost heating sources for a variety of applications. Ultra-high temperatures around 1000°C are high value and highly useful for energy-demanding industries. Many materials cannot withstand these conditions. In the area of Sustainable Chemicals, further limitations on material stability exist. Combining state-of-the-art materials with new designs provides a promising pathway for harvesting solar thermal energy and performing high temperature chemical processes. However, conventional manufacturing limits the potential for design flexibility. In this project, Additive Manufacturing was combined with advanced materials and new chemical reactor designs. In addition, 24/7 energy is necessary for chemical processing, and designs for ultra-high temperature thermal storage were devised. Specifically, preliminary design of a novel solar thermal receiver was developed in this project and designed to work with thermocatalytic reactors for producing sustainable chemicals and fuels. An ultra-high temperature particle storage system and heat exchangers were proposed to transport ultra-hot air as thermal fluid for the system. On a broader scale, this system could be used to tap solar thermal energy for a centralized facility with capability of transferring that heat to various segments at a full range of temperatures to 1000°C. The project pushed the temperature boundaries past those in current use, and Additive Manufacturing was envisaged for fabricating the receiver to meet requirements of extreme environments. An extensive analysis of silicon carbide additive manufacturing was performed to compare the thermal and mechanical properties of complex geometries compared to conventional material and those manufactured via other methods. The Additive Manufacturing via Binder-Jet printing was optimized and characterized to provide high quality and reproducible components capable of withstanding the proposed extreme environments. The designs for the concentrating solar thermal cavity with ultra-hot air thermal fluid showed high performance in simulations, attributable to the complex optimized geometries of the 3D printed systems. The bright future of Additive Manufacturing with advanced materials developments should provide more options and even higher quality as the technology further develops. Current costs for Additive Manufacturing of advanced ceramics is relatively low, however post-processing of the materials for extreme environments is currently high. There is little industrial-scale infrastructure for these, but it is growing as niche applications become more mainstream. The results of the project can be translated into similar extreme environments for concentrating solar thermal energy as well as its integration with ultra-hot air thermal fluids. A number of industries that require ultra-high temperatures need to electrify or otherwise decarbonize for climate goals, and this project showed that theoretically there is a pathway to do so with direct concentrated solar thermal power.

10 SYNTHETIC FUELS↗
DOE OSTI2022

High Sensitivity of Non–Fullerene Organic Solar Cells Morphology and Performance to a Processing Additive

Although solvent additives are used to optimize device performance in many novel non-fullerene acceptor (NFA) organic solar cells (OSCs), the effect of processing additives on OSC structures and functionalities can be difficult to predict. Here, two polymer-NFA OSCs with highly sensitive device performance and morphology to the most prevalent solvent additive chloronaphthalene (CN) are presented. Devices with 1% CN additive are found to nearly double device efficiencies to 10%. However, additive concentrations even slightly above optimum significantly hinder device performance due to formation of undesirable morphologies. A comprehensive analysis of device nanostructure shows that CN is critical to increasing crystallinity and optimizing phase separation up to the optimal concentration for suppressing charge recombination and maximizing performance. Here, domain purity and crystallinity are highly correlated with photocurrent and fill factors. However, this effect is in competition with uncontrolled crystallization of NFAs that occur at CN concentrations slightly above optimal. This study highlights how slight variations of solvent additives can impart detrimental effects to morphology and device performance of NFA OSCs. Furthermore, successful scale-up processing of NFA-based OSCs will require extreme formulation control, a tuned NFA structure that resists runaway crystallization, or alternative methods such as additive-free fabrication.

14 SOLAR ENERGY↗
DOE OSTI2022

How additives for tin halide perovskites influence the Sn 4+ concentration

Tin halide perovskite (Sn-HPs) photovoltaics could potentially equal or exceed the performance of their more toxic Pb-based analogues if defect state densities, particularly originating from the presence of Sn 4+ , can be significantly decreased. Numerous additives are incorporated into Sn-HPs to minimize the amount of Sn 4+ , including SnF 2 , reducing agents such as hydrazine derivatives, and various antioxidants. However, despite the frequent use of additives to reduce Sn 4+ content, there is limited understanding of how they function and consequently limited guidance for the development of new additives. Herein, we use cyclic voltammetry to probe the redox behavior of SnI 2 , SnI 4 , Sn-HP precursor solutions, and 18 different additives. Through 119 Sn NMR measurements we show that hydrochloride containing additives undergo halide exchange with SnI 4 to form SnI x Cl y , which results in decreased Sn 4+ concentrations and less p-type character in the Sn-HP films. We find that the most effective additive at lowering the Sn 4+ content in FASnI 3 is not capable of reducing SnI 4 or forming SnI x Cl y , but rather it acts as a sacrificial and coordinating antioxidant. In general, when selecting additives for Sn-HPs it is important to account for the redox potential, coordination with Sn species, ability to react with oxygen, and the potential for halide exchange.

36 MATERIALS SCIENCE↗
DOE OSTI2020

High Temperature Additive Architectures for 65% Efficiency (Final Report)

GE Power (GEP) proposed a development program that targets advanced high temperature additive components that contribute towards the DOE’s goal for advanced gas turbines that are capable of 65%, or greater, efficiency in combined cycle application. GEP proposed to leverage state-of-the-art additive manufacturing to develop novel and innovative component airfoil and end wall architectures that provide cooling flow savings while maintaining the component durability expected in today’s gas turbines. The objective of this program was to develop advanced component designs and architectures enabled by additive manufacturing, and the materials systems and additive manufacturing technology required for these designs. This Phase I program leveraged existing design and analysis knowledge and techniques for additive materials and methods and utilized extensive analytical evaluations to develop and refine designs for advanced turbine hot gas path (HGP) components. The design will be the basis for development and testing in a potential Phase II program. The goal of this Phase I program was to establish a feasible conceptual design for advanced additive turbine hot section components along with a technology maturation plan involving testing to address risk areas and needed validation. It was approached through two primary elements: 1) conceptual design and analysis of wall architectures, advanced airfoil cooling concepts, and advanced system-level concepts, and 2) investigation of additive modalities and associated materials systems. The Phase I program has concluded with the down-select of a primary design concept for a potential Phase II program.

36 MATERIALS SCIENCE↗
DOE OSTI2020

On the Robustness of Network Community Structure Under Addition of Edges

Communities represent important functional modules in networked systems. A key goal in preserving such communities is understanding their robustness under perturbations. Previous research has studied the impact of node removals and edge removals on the community structure. However, the impact of edge additions on the robustness of the community structure is relatively unknown. Edge additions or false positive edges may simulate measurement errors or external exceptional events that threaten the functionality of networked systems. Here, we study the impact of edge additions on the community structure using Lancichinetti-Fortunato-Radicchi (LFR) benchmark networks. We show that, for a fixed network size, the impact of edge additions is greater on networks with initially weak community structure than on networks with strongly clustered structures. In addition, we find that the perception of the impact is also dependent on the community detection algorithm used to uncover communities. In particular, we found that modularity-based methods such as Leiden and Louvain are less affected than information-theoretic and message passing-based methods such as Infomap and Label Propagation. Our results demonstrate that edge addition can (a) significantly impact the community structure of networks based on their initial conditions, and (b) the perception of the impact is dependent on the community detection algorithm used. We describe limitations, open challenges, and how this methodology can inform the design of resilient networked systems under edge additions.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

ETF Grout Expansion: Evaluation of MgO Additions and Struvite Precipitation Protocol for Potential Expansion

The ETF ammonia tolerant grout waste form was developed by the Vitreous State Laboratory (VSL) to stabilize ammonium and thereby prevent emission of ammonia vapor during solidification of an ammonium-rich, concentrated sulfate aqueous waste stream generated at the Hanford Effluent Treatment Facility (ETF). VSL did not observe expansion in samples prepared during the waste form development work. However, Savannah River National Laboratory (SRNL) personnel did encounter expansion, in some cases up to 20+ volume percent expansion in ETF grout samples while preforming work scope to evaluate compositional ranges for ETF brine and of the precipitation and solidification reagent. The work requests can be found in Washington River Protection Services (WRPS) Statement of Work (SOW), Requisitions #: 339922 Revisions 0 and 1, March 11, 2021, and November 2021. Additional evaluation was requested by WRPS SOW Requisitions #: 356730, Revision 1, February 1, 2022, to determine whether differences in the slags or differences in sample preparation protocols used by VSL and SRNL were the cause of the expansion observed in the SRNL samples. G. Chen, WRPS, arranged a materials exchange between VSL and SRNL and coordinated the VSL protocol for grouting and curing 1L of Base Case ETF simulant. Materials were exchanged between VSL and SRNL and both laboratories performed the VSL struvite precipitation-solidification protocol and cured samples for at least 28 days. VSL and SRNL encountered expansion, at varying degrees, in all samples prepared under the material exchange and grouting protocol. Additional material exchange testing between VSL and SRNL and alternative materials evaluation to further investigate the causes of grout expansion and differentiate the effects of various dry materials, grouting procedures, and curing containers was requested by WRPS SOW Requisitions #: 356730, Revision 2, January 10, 2023. Pacific Northwest National Laboratory (PNNL) assembled and distributed materials to both laboratories for testing. Observations from this study indicated variations in MgO additions, water-to-dry mix (dm) ratios and curing containers did not correlate to ETF ammonia grout expansion. In comparison to previous work, SRNL observed the addition rate of NaOH to be a potential factor for the final pH in the struvite precipitation step. In the current testing NaOH was added in bulk (5-10 mL at one time) during the precipitation step. The resulting pH was 7.57-9.15 which is slightly higher than pH observed at a slower addition rate. Additional testing is needed to identify the presence and/or struvite stability in high-pH struvite precipitant ETF ammonia grout samples. Therefore, based on current data, it is unknown if NaOH addition rate is the fundamental cause of grout expansion.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

Study of Additive Manufacturing Application to Geothermal Technologies

Geothermal reservoir characterization, field construction, and reservoir operations are very technology intensive activities that contribute significantly to the cost of delivering electricity produced from geothermal resources. Many geothermal technologies, such as downhole tools and drilling equipment, have unusual material, design, and manufacturing considerations dictated by the harsh geothermal environment and extreme aspect ratios required for deployment in a borehole. An additional challenge that faces geothermal applications is the low tool production volume needed to support the industry. Whereas tens of thousands of Oil & Gas wells are drilled and completed in the U.S. annually, there are typically only tens of geothermal wells that are drilled and completed. If a tool typically used in Oil & Gas applications cannot be directly used for geothermal, then the cost associated with making the tool suitable for geothermal is often prohibitive. There is therefore a much smaller inventory of technologies available to geothermal as compared to Oil & Gas and the level of efficiency and sophistication associated with field practice suffers accordingly. A number of advanced manufacturing methods, such as additive manufacturing, have received increased R&D as well as commercial attention in recent years because of their ability to rapidly prototype complex parts. Additive manufacturing in particular provides an opportunity to increase the technology available to the geothermal industry by either reducing fabrication costs associated with complex components or enabling economic production of low volume parts where specialized tooling is often required. Additional potential benefits of additive manufacturing include increased design freedom to make higher performing parts that cannot be made conventionally, the ability to integrate components into assemblies without joining operations, and the ability to economically fabricate variations on design in cases, such as casting molds, where there are large up-front costs associated with tooling. We have recently completed a study that investigated technology needs, representative use cases, manufacturability, and a techno-economic framework for comparing conventional to additive manufacturing methods for geothermal applications. This paper will provide an overview of this recent effort, describe the different elements of the assessment, and summarize the key takeaways related to both the feasibility of using additive manufacturing for geothermal technology applications as well as the potential benefits and impacts.

Polsky, Yarom↗
DOE OSTI2022

Combined Effects of Uniform Applied Pressure and Electrolyte Additives in Lithium-Metal Batteries

The development of lithium-metal batteries with good performance and long lifetimes requires fundamental insight into the mechanisms underlying performance improvements from individual design strategies and the interactions between multiple improvement approaches. Here, in this work, we investigated the individual and combined effects of applied pressure and a LiAsF 6 electrolyte additive on the performance of anode-free lithium-metal batteries; we employed various pressure application methods, which vary both in magnitude and uniformity. Both approaches individually improve cycling performance of anode-free lithium-metal batteries. Pressure increases the cycling efficiency at both the anode and cathode by promoting improved morphologies, while the LiAsF 6 additive additionally improves performance at the anode by enhancing the solid electrolyte interphase (SEI) properties. The combination of uniform applied pressure and a LiAsF 6 electrolyte additive produces lithium-metal batteries with cycling performance higher than can be achieved with either approach alone. This additional performance improvement is able to be realized due to the complementary rather than competitive nature of the mechanisms underlying applied pressure (lithium morphology) and electrolyte additives (SEI properties). Our results highlight the importance of moving beyond the investigation of isolated design strategies and demonstrate that superior cycling can be achieved by combining multiple approaches.

25 ENERGY STORAGE↗
DOE OSTI2024

Competition Between Growth and Removal in Zirconia Nanocrystal-Derived Tribofilms: The Role of Co-additives

Antiwear additives permit energy-efficient lubrication of gearboxes, bearings, and other tribological interfaces. We study zirconia (ZrO 2 ) nanocrystal additives, which readily form protective tribofilms in tribological contacts. Our prior work demonstrated cooperative antiwear performance between ZrO 2 and the S- and P-based co-additives in fully formulated hydrocarbon gear oils. Here, we extend that work by examining the growth kinetics of the ZrO 2 tribofilms, including the influence of the co-additives. In the boundary lubrication regime for mixed rolling-sliding contacts, the initial phase of ZrO 2 tribofilm growth is soon overtaken by removal processes, phenomena whose importance has gone unnoticed in prior work. Tribofilm removal affects the steady-state thickness and morphology of the tribofilm as well as its growth kinetics. The S- and P-based co-additives are incorporated into the ZrO 2 tribofilm, and alter the competition between the growth and removal processes, increasing initial net growth rates per contact cycle and contributing to a more polished final interface. This work highlights the significance of removal processes in determining tribofilm antiwear performance, and suggests several routes for improving tribofilm growth kinetics using co-additives.

Coadditives↗
DOE OSTI2025

Part distortion monitoring in additive manufacturing using machining

In additive manufacturing, accumulation of residual stresses can result in severe part distortion from the desired preform shape. Current methods for in-situ part distortion monitoring in additive manufacturing typically require expensive sensors, or capital equipment, and require time-consuming post-processing to understand the shape deviation. This paper presents an in-situ method, in the context of hybrid manufacturing, for part distortion detection using machining of additively manufactured parts. As a surrogate, three test artifacts were used to represent different distorted geometries. The tool axis positions from the machine tool controller and the cutting power were monitored during a facing operation. Cutting power data was used to detect the tool entry and exit in the workpiece using a novel approach with power standard deviation metric. The workpiece geometry and distorted configuration was subsequently predicted for positional and rotational deviations to within 2 mm accuracy using synchronized tool position data with cutting power. The proposed method can be used in a hybrid (additive and subtractive) machine tool to periodically check part distortion in the additive build. The method is applicable for any additive process and is low-cost and computationally inexpensive.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Elucidating Gas Reduction Effects of Organosilicon Additives in Lithium-Ion Batteries

Lithium-ion batteries (LIBs) with nonaqueous liquid electrolytes are prone to gas generation at elevated voltages and temperatures, degrading battery performance and posing serious safety risks. Organosilicon (OS) additives are an emerging candidate solution for gassing problems in LIBs, but a detailed understanding of their functional mechanisms remains elusive. In this work, we present a combined computational and experimental study to elucidate the gasreducing effects of OS additives. Cell volume measurements and gas chromatography–mass spectrometry reveal that OS additives can substantially reduce gas evolution in LIBs, particularly CO 2 regardless of source. Through density functional theory calculations, we identify multiple plausible pathways for CO 2 evolution, including (1) nucleophile-induced ring-opening of ethylene carbonate (EC) and the subsequent electro-oxidation and (2) direct electro-oxidation of lithium carbonate (Li 2 CO 3 ). Correspondingly, we find that OS additives function via two primary mechanisms: (1) scavenging of nucleophiles such as superoxide (O 2 •– ), peroxide (O 2 2– ), and carbonate ion (CO 3 2– ); (2) oligomerization with ethylene carbonate oxide ion and ethylene dicarbonate ion. Moreover, we discover that OS additives possess strong lithium coordination affinity, which helps further reduce the nucleophilic reaction energies and hence increases their nucleophile-scavenging efficiency. Finally, we provide a mechanistic interpretation for the enhanced gasreduction effects observed with fluorinated OS compounds, corroborated by surface analysis results from X-ray photoelectron spectroscopy. Our study offers the first molecular-level insights into how OS additives contribute to reduced gas formation in LIBs, paving the way for improved safety and performance of LIBs.

25 ENERGY STORAGE↗
DOE OSTI2024

Defect Production and Microstructural Feature Impact for Radiation Damage in Additively Manufactured 316 Stainless Steel

This milestone presents multi-scale modeling research results for additively manufactured 316 stainless steel. A combination of phase field, cluster dynamics, molecular dynamics, and density functional theory with machine learning is used, allowing for predictions of radiation-driven microstructural evolution in additively manufactured 316 stainless steel over a range of temperatures, damage rates, neutron spectra, and microstructures, and supporting the development of combined ion and neutron irradiation for material qualification. Informed by ion irradiation and neutron irradiation results across the Advanced Materials and Manufacturing Technologies program, we investigate the unique aspects of radiation-driven microstructure evolution in additively manufactured 316 stainless steel. In particular, we focus on understanding the impact of carbon concentration (varying, for example, between the 316L and 316H standards) on void formation; radiation-induced segregation at dislocation cells and grain boundaries; and the evolution of dislocation loops and network dislocation populations. We find that the unique characteristics of the additively manufactured microstructures must be accounted for in understanding the evolution of dislocation populations under thermal and irradiation conditions, such as the variation in sink strengths arising due to the variation in dislocation density. We also find that the radiation-induced segregation of Cr and Ni to grain boundaries and cell walls differs due to the differences in their defect sink biases. We also find that increasing the Ni content can slow vacancy diffusion, which may provide a mechanism for the observed reduction in transient swelling rate for austenitic Fe-Cr-Ni alloys with increasing Ni content. In addition, ion irradiations have shown that increasing carbon content in 316 SS results in a larger population of smaller voids, suggesting reduced vacancy diffusion. Our results show that the carbon content of additively manufactured 316 SS has a significant impact on the migration rate of defect clusters. The presence of carbon atoms results in carbon-vacancy trapping, significantly reducing the diffusion rate of vacancies. Carbon atoms may also be trapped near the surface of a void, which may reduce void growth by trapping vacancies that diffuse toward the void.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

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↗