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Section III Division 5 overview Code materials VHTR materials 617 and 800H Qualification of additional materials Corrosion effects Operating plant experience Additive/advanced manufacturing Control rod sleeves Pressure Vessel Steels Allowed materials Elevated temperature limits and properties Supply chain Welding Radiation damage
Cast superalloys have potential applications in space as impellers within closed-loop Brayton cycle nuclear power generation systems. Likewise wrought superalloys are good candidates for ducts and heat exchangers transporting the inert working gas in a Brayton-based power plant. Two cast superalloys, Mar-M247LC and IN792, and a NASA GRC powder metallurgy superalloy, LSHR, have been screened to compare their respective capabilities for impeller applications. Mar-M247LC has been selected for additional long term evaluations. Initial tests in helium indicate this inert environment may debit long term creep resistance of this alloy. Several wrought superalloys including Hastelloy(Registered TradeMark) X, Inconel(Registered TradeMark) 617, Inconel(Registered TradeMark) 740, Nimonic(Registered TradeMark) 263, Incoloy(Registered TradeMark) MA956, and Haynes 230 are also being screened to compare their capabilities for duct applications. Haynes 230 has been selected for additional long term evaluations. Initial tests in helium are just underway for this alloy. These proposed applications would require sufficient strength and creep resistance for long term service at temperatures up to 1200 K, with service times to 100,000 h or more. Therefore, long term microstructural stability is also being screened.
This report provides an economic analysis of CF8C-Plus and other candidate materials for Advanced Ultra Supercritical (AUSC) applications, including 347HFG, HR6W, Sanicro 25, Super 304H, Grade 92, SAVE12AD, Inconel 617, and Inconel 740H. An assessment of their moist air oxidation performance is also included. When compared with the aforementioned alloys, CF8C-Plus shows a favorable balance between cost, creep strength and moist air oxidation resistance in the temperature range of 600-700°C. Furthermore, its castability makes it additionally attractive from a manufacturing perspective. Materials with higher Ni content, such as HR6W, Sanicro 25, Inconel 617, and Inconel 740H, have better creep strength but the improved performance comes with increased cost. Stainless steel 347HFG exhibits inferior creep strength and lower moist air oxidation resistance, but at a greater cost, compared with CF8C-Plus. Super 304H, another stainless steel, has similar creep strength and cost compared to CF8CPlus at 700°C, but may not have as good moist air oxidation resistance. Grade 92 has lower creep strength and unfavorable economy compared with CF8C-Plus. SAVE12AD also has lower creep strength than CF8C-Plus, but has lower cost to use at 600°C. Both Grade 92 and SAVE12AD are also limited to the maximum use temperature of 649°C per ASME code case requirements.
Ongoing commercialization of different molten salt reactor concepts can considerably benefit from quantitative information on the impact of molten halide salts on the engineering properties such as creep and fatigue strength of materials of interest. Limited legacy data from the molten salt reactor experiment (MSRE) program showed a significant reduction in creep rupture strength of a Ni-base alloy in molten fluoride salt. This task evaluated the creep behavior of candidate structural materials 316H, 709 and 617 for advanced nuclear reactors under molten halide salt environments at 650, 700 and 750°C respectively. Creep tests were conducted in air, Ar, fluoride (FLiNaK) and chloride (NaCl-MgCl 2 ) salts. The molten salt environment caused a 50% reduction in creep rupture lifetime for 316H in FLiNaK and an 80% reduction in creep rupture lifetime in NaCl-MgCl 2 compared to air exposures. The molten fluoride salt environment resulted in almost a 90% and 50% reduction in creep rupture time for 709 and 617 irrespective of the cover gas environment (air and Ar). Significant differences in the compositional changes between the salt- and air-facing surfaces were observed in the alloy subsurface which might have potentially lead to formation of phases detrimental to the creep behavior.
Inconel 617 is a principal candidate material for helium gas cooled very-high-temperature reactors with outlet temperatures of 700–950 °C. Recent findings showed that this alloy develops unique surface oxide layers especially at high temperature (HT) helium environment with distinctive wear, friction and contact properties. This study investigates the elevated temperature mechanical properties of Inconel 617 top surface layers aged in HT helium environment. Nanoindentation technique is used to obtain load-displacement graphs of the alloy top surface oxide in temperatures ranging from 25 °C up to 600 °C. In addition, using finite element analysis along with an iterative regression technique, a semi-numerical method is developed to further measure and quantify the material parameters and, in particular, time-independent and creep characteristics of the oxide. Although Young's modulus of the oxide is found to be relatively close to the bulk for the tested temperatures, the yield strength and hardness, in comparison to the bulk material, increase significantly as the material is oxidized after aging. The oxide exhibits significant softening as the temperature increases to 600 °C. Unlike the bulk material, diffusion through the grains is found to be the dominant creep mechanism for the oxide. Considerable difference between the mechanical properties of the oxide and the bulk material shows the need for accurate measurements of near surface mechanical properties, if reliable predictive contact and tribological models are sought at elevated temperatures.
Nickel-based superalloys with superior thermochemical, mechanical, and tribological properties are highly utilized for critical components in several high temperature applications such as gas turbines and nuclear reactors. Inconel 617, in particular, is considered as one of the main candidate superalloys for tribo-components in very-high-temperature gas-cooled nuclear reactors. Recent findings indicate that this alloy grows unique surface oxide especially in a high-temperature helium environment with distinctive wear, friction, and contact properties. Here, this study investigates the high temperature contact area evolution and frictional behavior of Inconel 617 using finite element simulation and provides predictive models for the contact and friction performance at different normal loads, dwell times, and temperatures. High temperature helium-aged Inconel 617 top surface properties (up to 600 °C) are utilized along with a single asperity-based deformable elastic-plastic contact model under combined normal and tangential loading. Machine learning is used to assist the finite element results and to predict friction coefficient as well as contact area evolution. While a small difference is observed in the instantaneous friction coefficient (no dwell time) for all temperatures, friction coefficient increases considerably with dwell time. This shows that the effect of contact creep for longer dwell times significantly dominants the effect of high temperature variation in basic mechanical parameters such as modulus and yield strength. It is found that increasing temperature and dwell times lead to the friction coefficient increase, yet the dominance of dwell time effects decreases at higher temperatures and loads. While the analysis is presented for Inconel 617, the methodology is easy to be generalized and can be applied to other HT alloys.
This is the final report for the project on cold spray. The application of ball milling approach to prepare alloys of metal powder has been studied in this project.
Inconel 617 superalloy is a main candidate to be used for mechanical and tribo-components in high temperature helium-cooled reactors. Recent findings show that it grows a unique surface oxide, especially under high temperature helium with distinct wear, friction, and contact properties. Here, this study reports the elevated temperature nanoscratch behavior of Inconel 617 and further utilizes it to understand the effect of temperature on contact friction constituent contributors, adhesion and plowing at small scales. Inconel 617 is aged in high temperature helium, and consequently, the total kinetic friction coefficient of the alloy surface oxide is obtained in temperatures ranging from 25 °C to 400 °C. A finite element model is developed and validated based on the experimental results. The model is then utilized along with previously established techniques to determine the adhesion and plowing components of the friction coefficient. At small scale, the experimental results show that with increasing temperature the friction coefficient increases. It was inferred that this increase is mainly due to the increased contribution of plowing friction at high levels of deformation.
Experimental results are presented to show the effects of simulated reentry exposure by convective heating and by radiant heating on spectral and total emittance of statically oxidized Inconel 617 and Haynes HS188 superalloys to 1260 K and a silicide coatea (R512E) columbium 752 alloy to 1590 K. Convective heating exposures were conducted in a supersonic arc plasma wind tunnel using a wedge-shaped specimen configuration. Radiant tests were conducted at a pressure of .003 atmospheres of dry air at a flow velocity of several meters per second. Convective heating specimens were subjected to 8, 20, and 38 15-min heating cycles, and radiant heating specimens were tested for 10, 20, 50, and 100 30-min heating cycles. Changes in radiative properties are explained in terms of changes in composition resulting from simulated reentry tests. The methods used to evaluate morphological, compositional and crystallographic changes include: Auger electron spectroscopy; scanning electron microscopy; X-ray diffraction analysis; and electron microprobe analysis.
Inconel 617 is among the best candidates for utilization in high temperature gas cooled reactor tribo-components. However, the combined effects of sliding contact, along with intermittent idle times and very high temperature material degradation, deteriorates the alloy tribological performance, especially under a helium atmosphere. Laser peening is a surface treatment technique which can enhance the properties at the surface and subsurface by generating deep residual stresses and enhanced microstructure. In this work, we report the tribological behavior of regular laser peened as well as thermally-engineered laser peened Inconel 617 under helium and air atmospheres at 800 °C. In addition to friction and wear studies, the specimens are characterized by different analytical techniques to further understand the mechanisms involved in the peening process and sliding contact. Regardless of the peening process and post-process treatment types, it is observed that laser peening improves the tribological characteristics of Inconel 617. Interestingly, laser peening followed by helium thermal aging shows highly enhanced tribological behavior. This is attributed to the strengthening effect of the laser peening on the surface oxides providing an excellent and lasting protective and lubricating film under helium exposure.
The United States Department of Energy (DOE) has committed to expanding the domestic clean energy portfolio in response to the rising challenges of energy security in the wake of climate change. Accordingly, the construction of a series of Generation IV reactor technologies are being demonstrated, including sodium-cooled, small modular, and molten chloride fast reactors (MCFRs). To date, there are no fully qualified structural materials for constructing MCFRs. A number of commercial structural alloys have been considered for the construction of MCFRs, including alloys from the Inconel and Hastelloy series. Informed qualification of structural materials for the construction of MCFRs in the future can only be ensured by expanding the current fundamental knowledgebase of information pertaining to material performance under environmental stressors relevant to operation of the reactor, including corrosion susceptibility. The purpose of this investigation is to illustrate how a correlative multi-modal electron microscopy characterization approach, including the novel application of focused-ion beam 3D reconstruction capabilities, can elucidate the corrosion mechanism of a candidate structural material Inconel 617 for MCFR in NaCl-MgCl 2 eutectic salt at 700°C for 1,000 h. Evidence of intergranular corrosion, Ni and Fe dealloying, and Cr-O enrichment along the grain boundary, which most likely corresponds to Cr 2 O 3 , is a phenomenon that has been documented in other Ni-based superalloys exposed to chloride molten salt systems. Additional corrosion products, including the formation of insoluble MgAl 2 O 4 , within the porous network produced by the salt attack is a novel observation. In addition, Mo 3 Si 5 and τ 2 precipitates are detected in the alloy bulk and are dissolved by the salt. Furthermore, the lack of detection of design γ' precipitates in Inconel 617 after 1,000 h could indicate that the molten salt corrosion mechanism has indirectly induced a phase transformation of Al 2 TiNi (τ 2 ) and Ni 3 (Al,Ti) (γ’) phase. This investigation provides a comprehensive understanding of molten salt corrosion mechanisms in a complex material system such as a commercial structural alloy for applications in MCFRs.
Incoloy™ 800HT and Inconel™ 617 are primary candidate structural materials for high-temperature gas-cooled reactors (HTGRs). Impurities (e.g., H 2 O, CH 4 ) in the coolant induce corrosion reactions that affect tribological behavior. We investigate the high-temperature tribological performance of the alloys under surface conditions including: conditioned in H 2 O-containing helium at elevated temperatures, hardened via the carbon-diffusion Kolsterising® treatment, and conditioned after hardening. Initial friction coefficients and volume removed serve as metrics for wear performance. In this work, we find that wear mechanisms including scuffing, glaze-oxide formation, and oxide-layer wear and break-through are governed by surface hardness, chemistry, and applied load. The formation of a glaze-oxide layer is achieved with an oxide of sufficient mechanical integrity if the oxide-substrate interface is strong and the load is low.
Inconel 617 is a nickel-based superalloy which is being considered for heat-shield applications because of its high-temperature strength, good oxidation resistance and high emittance of oxidized surfaces. While the effects of simulated reentry conditions on emittance and oxidation of Inconel 617 have been studied, the combined effects of the ground-based environment with sea salt exposure and the reentry environment have not been evaluated. Experimental results are presented to show the effects of environmental simulation including ground-based and reentry exposure on the emittance and oxidation of Inconel 617. Specimens were exposed to simulated reentry at a surface temperature of 2000 F in the Langley Research Center Hypersonic Materials Environmental Test System (HYMETS) Facility with and without alternate exposures to an atmospheric seashore environment or a laboratory sea salt environment. This paper presents emittance, mass loss, oxide chemistry, and alloy composition data for the specimens.
Inconel 617 is a nickel-based superalloy which is being considered for heat-shield applications because of its high-temperature strength, good oxidation resistance and high emittance of oxidized surfaces. While the effects of simulated reentry conditions on emittance and oxidation of Inconel 617 have been studied, the combined effects of the ground-based environment with sea salt exposure and the reentry environment have not been evaluated. Experimental results are presented to show the effects of environmental simulation including ground-based and reentry exposure on the emittance and oxidation of Inconel 617. Specimens were exposed to simulated reentry at a surface temperature of 2000 F in the Langley Research Center Hypersonic Materials Environmental Test System (HYMETS) Facility with and without alternate exposures to an atmospheric seashore environment or a laboratory sea salt environment. This paper presents emittance, mass loss, oxide chemistry, and alloy composition data for the specimens.
Statically oxidized Inconel 617 and MA 956 superalloys were prepared with vapor deposited aluminosilicate layers and exposed to temperatures which simulated reentry conditions. The aluminosilicate layers were 1-2 microns thick. The trials consisted of exposures to 1500-2300 F heat while surface temperatures were monitored with pyrometers. Analyses were then performed of the catalytic activity, oxidation phenomena, and radiative properties after thermal cycling the specimens for 8 hr. Both alloys were found to be catalytic to the recombination processes of dissociated species in the reentry environment. The coatings reduced the catalytic activity by 40 percent for both alloys but did not change the emittance. An enhanced Cr depletion zone was detected in the Inconel samples, implying that the coating did not prevent diffusion loss of Cr. The coated MA 956, on the other hand, gained weight over the course of the trials.
Addressing the escalating demand for critical minerals (CMs) driven by global climate change initiatives, this study explores compositional modifications to Inconel 617 (IN617) by substituting cobalt (Co) with manganese (Mn) across various atomic percentages. Here, we conducted a computational feasibility study employing Molecular Dynamics (MD) simulations to provide strategic guidance for experimental validation. The simulations analyzed tensile strength and corrosion resistance for five modified compositions (M1 to M5) to identify optimal properties. Tensile tests on cubic simulation cells were performed to generate stress-strain curves, revealing the impact of Co replacement with Mn on tensile strength—a metric correlated with hardness. Oxygen penetration simulations were conducted to evaluate corrosion resistance, indicating that reduced oxygen penetration depth corresponds to enhanced resistance. Promising compositions underwent phase diagram calculations for assessing phase stability. The optimal composition (M1), characterized by high tensile strength and minimal oxygen penetration, was chosen for experimental validation using induction melting and friction stir consolidation techniques. The materials were further characterized using SEM-EDS, XRD, and Vickers hardness testing. Our findings suggest that Mn substitution in IN617 can yield mechanical performance at par with high-Co alloys in energy-critical applications.