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DOE OSTI2026

Mechanical characterization of fine-grain dispersion-strengthened tungsten as a plasma facing material

Field-Assisted Sintering Technology (FAST) was used to produce fine-grained, dispersion-strengthened tungsten (W) materials. Investigated materials 4138, 4353, and 4355 composed of 3 wt% ZrC sintered at 1800 °C, 5 wt% ZrC sintered at 1800 °C, and 3 wt% ZrC sintered at 2000 °C, respectively. They were compared against ITER-grade W. A series of mechanical and thermal property testing and microstructure studies were conducted to study them as a potential plasma facing material (PFM) for fusion reactors. Hardness testing showed that manufacturing conditions substantially altered hardness. Material 4355 had an average HV10 value of 497.2 ± 16.8, slightly higher than ITER-grade at 378.5 ± 40.3. However, material 4353 was substantially higher with an HV10 value of 738.9 ± 31.7 over the investigated temperature range. Electron Backscatter Diffraction (EBSD) analysis showed that FAST produced substantially smaller grains than the hot-rolled ITER-grade W material, offering notable control over grain size. Materials 4353 and 4355 had grain sizes of 0.44 ± 0.20 µm and 3.67 ± 0.89 µm, respectively, whereas ITER-grade 27.14 ± 19.76 µm at room temperature. The fine grain structures showed no net coarsening after 1 hr. anneals up to 1800 °C, several hundred degrees above the 1100 – 1500 °C recrystallization range reported for conventional W. Inverse application of the Zener pinning relationship to the measured grain sizes indicates that these two FAST sintering conditions produce markedly different effective dispersoid populations, with effective particle diameters of approximately 90 nm at a peak sintering temperature of 1800 °C and approximately 460 nm at 2000 °C, respectively. This result demonstrates that the FAST thermal condition itself, and not the nominal ZrC content alone, governs the pinning effectiveness of the dispersion. Thermal diffusivity measurements support this finding independently. Materials of identical composition sintered at different temperatures differ by approximately 19% in measured thermal diffusivity with statistically indistinguishable density, while materials of different composition and sintering temperature converge to within approximately 2%. At a representative divertor heat flux of 10 MW/m², the lower thermal conductivity of the fine-grained materials corresponds to approximately 28 to 33 °C per millimeter of armor thickness relative to ITER-grade W, traded against a substantially larger margin to recrystallization-driven degradation. While high temperature tensile testing revealed likely contamination that motivates refinement of the manufacturing process, FAST-produced, fine-grained, dispersion-strengthened W offers process-controlled microstructural stability well above the operating temperatures of conventional W and supports its continued development as a PFM for economically viable commercial fusion power.

Parker, Gabe [ORNL] (ORCID:0000000190394100)↗

DOE OSTI2020

An Overview of Gemma FY20 Verification Activities

Gemma verification activities for FY20 can be divided into three categories: the development of specialized quadrature rules, initial progress towards the development of manufactured solutions for code verification, and automated code-verification testing. In the method-of-moments implementation of the electric-field integral equation, the presence of a Green’s function in the four-dimensional integrals yields singularities in the integrand when two elements are nearby. To address these challenges, we have developed quadrature rules to integrate the functions through which the singularities can be characterized. Code verification is necessary to develop confidence in the implementation of the numerical methods in Gemma. Therefore, we have begun investigating the use of manufactured solutions to more thoroughly verify Gemma. Manufactured solutions provide greater flexibility for testing aspects of the code; however, the aforementioned singularities provide challenges, and existing work is limited in rigor and quantity. Finally, we have implemented automated code-verification testing using the VVTest framework to automate the mesh refinement and execution of a Gemma simulation to generate mesh convergence data. This infrastructure computes the observed order of accuracy from these data and compares it with the theoretical order of accuracy to either develop confidence in the implementation of the numerical methods or detect coding errors.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2025

Phase-field model of alloy solidification far from chemical equilibrium at the solid-liquid interface

We further develop a recently introduced phase-field model of far-from-equilibrium alloy solidification under additive manufacturing conditions [K. Ji et al., Phys. Rev. Lett. 130, 026203 (2023)]. This model utilizes enhanced solute diffusivity within the spatially diffuse interface region to quantitatively capture solute trapping with a larger interface width, thereby making simulations on experimentally relevant length and timescales computationally feasible. The main developments presented here include testing the robustness of different variational formulations, extending the model to concentrated alloys by incorporating solid and liquid free energies from thermodynamic databases, as illustrated for hypoeutectic Al-Ag alloys with CALPHAD, extending convergence tests as a function of interface width to 3D, and carrying out simulations in both 2D and 3D to examine existing theories of microstructure development. Our results indicate that the simplest variational formulation that interpolates the bulk free-energy density between its solid and liquid forms is the most robust. Remarkably, for hypoeutectic Al-Ag alloys, this formulation yields a high-velocity nonequilibrium phase diagram that is independent of interface width, thereby demonstrating that the framework of enhanced solute diffusivity can be nontrivially extended to concentrated alloys. Other variational formulations have restricted ranges of materials or processing parameters that can be reliably modeled. We use 2D simulations to construct high-velocity microstructure selection maps for dilute Al-Cu alloys. The results validate the important role of latent heat rejection at the interface and extend the limited predictions of linear stability analysis [A. Karma and A. Sarkissian, Phys. Rev. E 47, 513 (1993)] and sharp-interface 1D simulations to fully nonlinear regimes. Furthermore, 3D simulations, carried out using a computationally tractable axisymmetric cellular/dendritic interface shape, demonstrate a good convergence similar to that observed in 2D as a function of interface width. Full 3D simulations, in turn, reveal that the standard theory of absolute stability is a good predictor of the upper critical velocity beyond which steady-state growth becomes unstable, despite the different morphological manifestations of this instability in 2D and 3D.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Modeling gas–shell mixing in ICF with separated reactants

Mixing between fuel and shell materials in ICF implosions can affect implosion dynamics and even prevent ignition. We use data from a series of separated reactant experiments on the National Ignition Facility to calibrate and test the predictive power of gas–shell mix models. Two models are used to estimate fuel–shell mix: a Reynolds-averaged turbulence model and molecular diffusion. Minor uncertainties in capsule manufacture, experimental conditions, and values for mix model parameters produce significant variation in simulation results. Using input/output pairs from 1D simulations, we train Gaussian process surrogate models to predict experimental quantities of interest. The surrogates are used to construct posteriors for mix model parameters by marginalizing over uncertainties in capsule manufacture and experimental conditions. Mix models are calibrated with a subset of experimental data (neutron yields, ion temperature, and bang time) and tested using the remaining data. In general, both the diffusion and turbulence model correctly predict experimental DT and TT neutron yields. Despite having more free parameters, the turbulence model underpredicts ion temperature at high convergence ratio. Furthermore, the simpler diffusion model correctly predicts these temperatures, suggesting nonhydrodynamic gas–shell mix. The computational model consistently overpredicts DD neutron yield, indicating possible shortcomings outside of the mix model.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS1998

The Strutjet Rocket Based Combined Cycle Engine

The multi stage chemical rocket has been established over many years as the propulsion System for space transportation vehicles, while, at the same time, there is increasing concern about its continued affordability and rather involved reusability. Two broad approaches to addressing this overall launch cost problem consist in one, the further development of the rocket motor, and two, the use of airbreathing propulsion to the maximum extent possible as a complement to the limited use of a conventional rocket. In both cases, a single-stage-to-orbit (SSTO) vehicle is considered a desirable goal. However, neither the "all-rocket" nor the "all-airbreathing" approach seems realizable and workable in practice without appreciable advances in materials and manufacturing. An affordable system must be reusable with minimal refurbishing on-ground, and large mean time between overhauls, and thus with high margins in design. It has been suggested that one may use different engine cycles, some rocket and others airbreathing, in a combination over a flight trajectory, but this approach does not lead to a converged solution with thrust-to-mass, specific impulse, and other performance and operational characteristics that can be obtained in the different engines. The reason is this type of engine is simply a combination of different engines with no commonality of gas flowpath or components, and therefore tends to have the deficiencies of each of the combined engines. A further development in this approach is a truly combined cycle that incorporates a series of cycles for different modes of propulsion along a flight path with multiple use of a set of components and an essentially single gas flowpath through the engine. This integrated approach is based on realizing the benefits of both a rocket engine and airbreathing engine in various combinations by a systematic functional integration of components in an engine class usually referred to as a rocket-based combined cycle (RBCC) engine. RBCC engines exhibit a high potential for lowering the operating cost of launching payloads into orbit. Two sources of cost reductions can be identified. First, RBCC powered vehicles require only 20% takeoff thrust compared to conventional rockets, thereby lowering the thrust requirements and the replacement cost of the engines. Second, due to the higher structural and thermal margins achievable with RBCC engines coupled with a higher degree of subsystem redundance lower maintenance and operating cost are obtainable.

Siebenhaar, A.↗

NASA NTRS2001

Calibration of Gyros with Temperature Dependent Scale Factors

The general problem of gyro calibration can be stated as the estimation of the scale factors, misalignments, and drift-rate biases of the gyro using the on-orbit sensor measurements. These gyro parameters have been traditionally treated as temperature-independent in the operational flight dynamics ground systems at NASA Goddard Space Flight Center (GSFC), a scenario which has been successfully applied in the gyro calibration of a large number of missions. A significant departure from this is the Microwave Anisotropy Probe (MAP) mission where, due to the high thermal variations expected during the mission phase, it is necessary to model the scale factors as functions of temperature. This paper addresses the issue of gyro calibration for the MAP gyro model using a manufacturer-supplied model of the variation of scale factors with temperature. The problem is formulated as a least squares problem and solved using the Levenberg-Marquardt algorithm in the MATLAB(R) library function NLSQ. The algorithm was tested on simulated data with Gaussian noise for the quaternions as well as the gyro rates and was found to consistently converge close to the true values. Significant improvement in accuracy was noticed due to the estimation of the temperature-dependent scale factors as against constant scale factors.

Belur, Sheela V.↗

DOE OSTI2026

Algebraic Multigrid with Filtering: An Efficient Preconditioner for Interior Point Methods in Large-Scale Contact Mechanics Optimization

Large-scale contact mechanics simulations are crucial in many engineering fields such as structural design and manufacturing. In the frictionless case, contact can be modeled by minimizing an energy functional; however, these problems are often nonlinear, nonconvex, and increasingly difficult to solve as mesh resolution increases. In this work, we employ a Newton-based interior-point (IP) filter line-search method, an effective approach for large-scale constrained optimization. While this method converges rapidly, each iteration requires solving a large saddle-point linear system that becomes ill-conditioned as the optimization process converges, largely due to IP treatment of the contact constraints. Such ill-conditioning can hinder solver scalability and increase iteration counts with mesh refinement. Here, to address this, we introduce a novel preconditioner, algebraic multigrid with filtering (AMGF), tailored to the Schur complement of the saddle-point system. Building on the classical AMG solver, commonly used for elasticity, we augment it with a specialized subspace correction that filters near null space components introduced by contact interface constraints. Through theoretical analysis and numerical experiments on a range of linear and nonlinear contact problems, we demonstrate that the proposed solver achieves mesh independent convergence and maintains robustness against the ill-conditioning that notoriously plagues IP methods. These results indicate that AMGF makes contact mechanics simulations more tractable and broadens the applicability of Newton-based IP methods in challenging engineering scenarios. More broadly, AMGF is well suited for problems, optimization or otherwise, where solver performance is limited by a low-dimensional subspace, such as those arising from localized constraints, interface conditions, or model heterogeneities. This makes the method widely applicable beyond contact mechanics and constrained optimization.

Mathematics and Computing↗

NASA NTRS1992

Small Business Innovations (Helicopters)

The amount of engine power required for a helicopter to hover is an important, but difficult, consideration in helicopter design. The EHPIC program model produces converged, freely distorted wake geometries that generate accurate analysis of wake-induced downwash, allowing good predictions of rotor thrust and power requirements. Continuum Dynamics, Inc., the Small Business Innovation Research (SBIR) company that developed EHPIC, also produces RotorCRAFT, a program for analysis of aerodynamic loading of helicopter blades in forward flight. Both helicopter codes have been licensed to commercial manufacturers.

Source record↗

NASA NTRS1994

A neural network controller for automated composite manufacturing

At McDonnell Douglas Aerospace (MDA), an artificial neural network based control system has been developed and implemented to control laser heating for the fiber placement composite manufacturing process. This neurocontroller learns an approximate inverse model of the process on-line to provide performance that improves with experience and exceeds that of conventional feedback control techniques. When untrained, the control system behaves as a proportional plus integral (PI) controller. However after learning from experience, the neural network feedforward control module provides control signals that greatly improve temperature tracking performance. Faster convergence to new temperature set points and reduced temperature deviation due to changing feed rate have been demonstrated on the machine. A Cerebellar Model Articulation Controller (CMAC) network is used for inverse modeling because of its rapid learning performance. This control system is implemented in an IBM compatible 386 PC with an A/D board interface to the machine.

Lichtenwalner, Peter F.↗

NASA NTRS1984

Numerical modeling of turbulent flow

Three dimensional combustor calculations are currently stretching the computer hardware capabilities and the computing budgets of gas turbine manufacturers. One of the main reasons for this relates to the large number of complex physical processes occurring in the combustor. Airflow, fuel spray, reaction kinetics, flame radiation, and not the least of which, turbulence must be modeled and the related differential equations solved. Discussions in this conference will address methods to improve the accuracy of combustor flow field calculations and methods to speed the convergence of the modeled equations. This report will focus on aspects of merging these two new technologies. The improved accuracy discretization schemes have a negative impact on the speed of convergence of the modeled equations that the improved solution algorithms may not overcome. A description of the causes of this problem and potential solutions will be examined.

Claus, R. W.↗

NASA NTRS2026

Development and Experimental Validation of a Path-Dependent Spin Forming Finite Element Model

Spin forming is an advanced manufacturing process widely used in the aerospace and defense sectors to produce lightweight, high-strength cylindrical components with tight dimensional tolerances. This study explores the applicability of the path-dependent Mechanical Threshold Stress (MTS) constitutive model by simulating the evolution of geometry, machining forces, and plastic deformation during the spin forming of a 10-mm thick 6061-O aluminum cylinder. While numerical modeling of spin forming has advanced substantially over the past decade, systematic verification and experimental validation of material models remain limited, particularly in predicting through-thickness process evolution. The MTS model, incorporating a Voce hardening rule, is employed for its ability to represent cyclic loading, rapidly varying temperature fields, and strain rates characteristic of spin forming. Numerical convergence analysis indicates discretization uncertainties between 0.3% and 9.2% for key quantities of interest. Experimental validation demonstrates that the MTS model, when implemented with a verified mesh, accurately reproduces both elastic and plastic behavior of 6061-O aluminum, predicting peak roller loads within 11–18% of measurements, geometric tolerances within 3%, and plastic strain distributions within 10% of experimental values. Collectively, these results establish a validated computational framework for predictive spin-forming simulations with quantified confidence, providing a foundation for extension to other alloys, geometries, and forming conditions.

Spin forming↗

DOE OSTI2020

Stereoscopic high-speed microscopy to understand transient internal flow processes in high-pressure nozzles

The flow and cavitation behavior inside fuel injectors is known to affect spray development, mixing and combustion characteristics. We discuss that while diesel fuel injectors with converging and hydro-eroded holes are generally known to limit cavitation and feature higher discharge coefficients during the steady period of injection, less is known about the flow during transient periods corresponding to needle opening and closing. Multiple injection strategies involve short injections, multiplying these aspects and giving them a growing importance as part of the fuel delivery process. In this study, single-hole transparent nozzles were manufactured with the same hole inlet radius and diameter as the Engine Combustion Network Spray D nozzle, mounted to a modified version of a common-rail Spray A injector body and needle. Needle opening and closing periods were visualized with stereoscopic high-speed microscopy at injection pressures relevant to modern diesel engines. Time-resolved sac pressure was extracted via elastic deformation analysis of the transparent nozzles. Sources of cavitation were observed and tracked, enabling the identification of a gas exchange process after the end of injection with ingestion of chamber gas into the sac and orifice. We observed that the gas exchange contributed widely to disrupting the start of injection and outlet flow during the subsequent injection event.

42 ENGINEERING↗

DOE OSTI2026

Designing the Protocols for Programmable Ammonia Catalysis

Programmable catalysis can provide a more energy-efficient and cost-effective route to enhancing commercial ammonia production, a key process in the advancement of renewable energy technologies and the manufacture of fertilizers and basic chemicals. This work explores the computational discovery of optimal forcing protocols to drive such dynamic catalysis models. By employing matrix-free time-stepper methods, coupled with an optimization approach, that integrates Bayesian optimization with a Bayesian continuation strategy to efficiently discover the periodic steady states of such periodically forced systems, we enable the discovery of complex optimal catalyst strain waveforms, while ensuring robust solver convergence. We demonstrate the flexibility of our approach to discover optimized forcing protocols under varying physical constraints on strain modulation or other catalyst operating parameters. We show that these can have a temporal structure more complex than simple step functions. In order to detect undesirable catalytic loops that may correlate with overall reduced performance, we perform a study using graph-theoretical analysis to investigate the dynamics of catalytic kinetic networks formed.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS2000

Performance of the OVERFLOW-MLP and LAURA-MLP CFD Codes on the NASA Ames 512 CPU Origin System

The shared memory Multi-Level Parallelism (MLP) technique, developed last year at NASA Ames has been very successful in dramatically improving the performance of important NASA CFD codes. This new and very simple parallel programming technique was first inserted into the OVERFLOW production CFD code in FY 1998. The OVERFLOW-MLP code's parallel performance scaled linearly to 256 CPUs on the NASA Ames 256 CPU Origin 2000 system (steger). Overall performance exceeded 20.1 GFLOP/s, or about 4.5x the performance of a dedicated 16 CPU C90 system. All of this was achieved without any major modification to the original vector based code. The OVERFLOW-MLP code is now in production on the inhouse Origin systems as well as being used offsite at commercial aerospace companies. Partially as a result of this work, NASA Ames has purchased a new 512 CPU Origin 2000 system to further test the limits of parallel performance for NASA codes of interest. This paper presents the performance obtained from the latest optimization efforts on this machine for the LAURA-MLP and OVERFLOW-MLP codes. The Langley Aerothermodynamics Upwind Relaxation Algorithm (LAURA) code is a key simulation tool in the development of the next generation shuttle, interplanetary reentry vehicles, and nearly all "X" plane development. This code sustains about 4-5 GFLOP/s on a dedicated 16 CPU C90. At this rate, expected workloads would require over 100 C90 CPU years of computing over the next few calendar years. It is not feasible to expect that this would be affordable or available to the user community. Dramatic performance gains on cheaper systems are needed. This code is expected to be perhaps the largest consumer of NASA Ames compute cycles per run in the coming year.The OVERFLOW CFD code is extensively used in the government and commercial aerospace communities to evaluate new aircraft designs. It is one of the largest consumers of NASA supercomputing cycles and large simulations of highly resolved full aircraft are routinely undertaken. Typical large problems might require 100s of Cray C90 CPU hours to complete. The dramatic performance gains with the 256 CPU steger system are exciting. Obtaining results in hours instead of months is revolutionizing the way in which aircraft manufacturers are looking at future aircraft simulation work. Figure 2 below is a current state of the art plot of OVERFLOW-MLP performance on the 512 CPU Lomax system. As can be seen, the chart indicates that OVERFLOW-MLP continues to scale linearly with CPU count up to 512 CPUs on a large 35 million point full aircraft RANS simulation. At this point performance is such that a fully converged simulation of 2500 time steps is completed in less than 2 hours of elapsed time. Further work over the next few weeks will improve the performance of this code even further.The LAURA code has been converted to the MLP format as well. This code is currently being optimized for the 512 CPU system. Performance statistics indicate that the goal of 100 GFLOP/s will be achieved by year's end. This amounts to 20x the 16 CPU C90 result and strongly demonstrates the viability of the new parallel systems rapidly solving very large simulations in a production environment.

Taft, James R.↗

DOE OSTI2024

Inaugural Molten Salt Technologies Workshop Powering the Future

The inaugural “Molten Salt Technologies – Powering the Future” Workshop marked a significant convergence of minds from diverse industries, each harnessing molten-salt technologies in innovative ways. Participants from sectors such as solar, geothermal, and advanced nuclear energy, as well as those involved in cutting-edge applications like thermal transport and rare-earth metals extraction, gathered to discuss their shared technical challenges and opportunities. Industry leaders in metal extraction and recycling, alongside experts in high-temperature sensor technology and advanced material manufacturing, also brought their unique perspectives to the table. This workshop served as a crucial platform for these varied industries to delve into the engineering intricacies that molten salt technologies entail. Common challenges such as understanding the thermophysical properties of salts, tackling corrosion mechanisms in harsh environments, and enhancing material resilience under extreme conditions were at the forefront of discussions. These technical sessions highlighted the critical need for cross-industry collaboration to address issues like salt life-cycle process engineering, impurity mitigation, and the development of durable, high-performance materials. By bringing together academia, industry, and representatives from national laboratories and the U.S. Department of Energy (DOE), the workshop facilitated a rich exchange of knowledge and experiences. This interaction not only fostered new partnerships but also strengthened the network among existing collaborators, setting the stage for joint solutions to the complex problems faced by all sectors using molten salt technologies. The event underscored the importance of collaborative efforts in overcoming common engineering challenges and advancing the application of molten-salt technologies across various industries. The workshop not only provided an essential forum for networking and idea exchange but also highlighted the collective drive towards innovative solutions that could benefit multiple fields.

Department of Energy↗

DOE OSTI2024

Inaugural Molten Salt Technologies Workshop Powering the Future

Department of Energy↗

DOE OSTI2023

Workshop on Addressing Rigor and Reproducibility in Thermal, Heterogeneous Catalysis

Heterogeneous catalysis has long served as the bedrock of the manufacturing of energy carriers, fuels and chemicals, and various technologies for pollution abatement. The significant complexity and variability spanning the entire breadth of catalyst material properties, synthesis methods, characterization techniques, and evaluation procedures, has focused attention on the need to establish community-accepted best practices for ensuring high-quality, benchmarked, and reproducible data. In addition, increased societal urgency to transition to clean energy and reduce greenhouse gas concentrations has incentivized interdisciplinary, convergent, and translational approaches to catalysis research in recent years. Research engineers and scientists with expertise cutting broadly across materials science, chemical synthesis, interfacial science, spectroscopy, and methods of data science and computational simulation, all bring diverse and important perspectives to catalysis research, but often with little awareness of the complexity of catalytic systems, especially in their working environment. As has already occurred in other scientific fields, there has been growing recognition and consensus in the heterogeneous catalysis research community that mechanisms are needed to improve the rigor and reproducibility (R&R) of experimental measurements, to ensure alignment of the broader research community with a common core of best practices specific to the realization of high-quality catalysis research. Similarly, the field is moving rapidly toward computationally informed and data science-driven catalyst design, but the success of implementing such predictive tools hinges on model training and validation rooted in rigorously obtained and reproducible experimental data that are benchmarked to common specifications. As such, this workshop was convened to prepare a report summarizing best practices for reporting data and performing experiments that researchers can use to benchmark, validate, and reproduce data in specific sub-fields of thermal, heterogeneous catalysis. Additionally, we discussed recommendations for future actions that may improve R&R in this field. The workshop organizers and participants include a diverse range of catalysis researchers from various employment sectors (e.g., academia, industry, national laboratory), institutional mission and resources (e.g., PhD-granting research universities, non-PhD-granting teaching universities), career stage (e.g., early, mid and late-career), technical expertise, and demographic background. This diverse group was involved in the discussion of workshop agenda items, writing this report, and discussing possible future action items for the community to consider, which helped ensure that a broad range of perspectives were captured in the description of the problems at hand and the creation of actionable solutions that may be effectively adopted by the diverse practitioners in catalysis research. Importantly, this group of workshop participants also included very early career researchers (e.g., senior PhD students, postdoctoral scholars) who will become the next generation of scientific leaders in various sectors, thus capturing emerging perspectives of newcomers to the field to shape its future while positively impacting the development of its future workforce. We envision that this effort will help advance the field of catalysis science by improving the rigor and reproducibility of experimental data collected by current researchers and future newcomers to the field, which is of broad importance to health and vitality of any scientific discipline. Therefore, best practices identified in this endeavor for thermal heterogeneous catalysis can be translated to such efforts in other areas of catalysis and other scientific fields involving the study of materials, and vice versa. We also envision this to be an ongoing effort, with future workshops that are convened to discuss issues of rigor and reproducibility on technical topics that were unable to be covered in this workshop due to its scope limitations, and as emerging methods and materials become more prevalent in the research community.

36 MATERIALS SCIENCE↗

DOE OSTI2021

An investigation into the effects of cyclic strain rate on the high cycle and very high cycle fatigue behaviors of wrought and additively manufactured Inconel 718

Additive Manufacturing (AM) has increasingly been used to fabricate parts in aerospace applications, which may require service lives beyond ten-million cycles due to the imposed high loading frequencies. Understanding the very high cycle fatigue (VHCF) behavior of these additive manufactured (AM) parts is an important step towards their design and qualification processes. This study focuses on the high cycle fatigue (HCF) and VHCF behaviors of both wrought and laser beam-powder bed fusion (LB-PBF) fabricated Inconel 718 in machined/polished surface condition, emphasizing on the influence of test frequency (i.e., cyclic strain rate). Uniaxial, fully-reversed force- and stress-controlled fatigue tests were conducted utilizing a servo-hydraulic and an ultrasonic test system operating at 5 Hz and 20 kHz, respectively, on wrought as well as LB-PBF vertically and diagonally built specimens. Fatigue cracks in the majority of the specimens were found to initiate from intra-granular slip bands near or at the surface, which gives rise to strong anisotropy in fatigue resistance in LB-PBF specimens due to the presence of columnar grains along the build directions. Longer fatigue lives were obtained at 20 kHz, which was ascribed to possibly lower-than-intended stresses applied in the ultrasonic tests. The corrected stress-life fatigue data at 20 kHz were found to converge to the one obtained from conventional testing at 5 Hz, implying no effect of cyclic strain rate on the fatigue behavior of Inconel 718 regardless of the fabrication process. The findings of this work confirm the use of ultrasonic fatigue testing to expedite generation of AM materials data to keep up with the current demand; however, the applied stress may need to be corrected.

36 MATERIALS SCIENCE↗