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At least 1,225 records · Page 68

Graphite Microstructural Characterization Using Time-Domain and Correlation-Based Ultrasonics

Among techniques that have been used to determine elastic modulus in nuclear graphites, ultrasonic methods have enjoyed wide use and standards using contacting piezoelectric tranducers have been developed to ensure repeatability of these types of measurements. However, the use of couplants and the pressures used to effectively couple transducers to samples can bias measurements and produce results that are not wholly related to the properties of the graphite itself. In this work, we have investigated the use of laser ultrasonic methods for making elastic modulus measurements in nuclear graphites. These methods use laser-based transmitters and receivers to gather data and do not require use of ultrasonic couplants or mechanical contact with the sample. As a result, information directly related to the elastic responses of graphite can be gathered even if the graphite is porous, brittle and compliant. In particular, we have demonstrated the use of laser ultrasonics for the determination of both Young’s modulus and shear modulus in a range of nuclear graphites including those that are being considered for use in future nuclear reactors. These results have been analyzed to assess the contributions of porosity and microcracking to the elastic responses of these graphites. Laser-based methods have also been used to assess the moduli of NBG-18 and IG-110 where samples of each grade were oxidized to produce specific changes in porosity. These data were used to develop new models for the elastic responses of nuclear graphites and these models have been used to infer specific changes in graphite microstructure that occur during oxidation that affect elastic modulus. Specifically, we show how ultrasonic measurements in oxidized graphites are consistent with nano/microscale oxidation processes where basal plane edges react more readily than basal plane surfaces. We have also shown the use of laser-based methods to perform shear-wave birefringence measurements and have shown how these measurements can be used to assess elastic anisotropy in nuclear graphites. Using models developed in this program, ultrasonic data were interpreted to extract orientation distribution coefficients that could be used to represent anisotropy in these materials. This demonstration showed the use of ultrasonic methods to quantify anisotropy and how these methods provide more detailed information than do measurements of thermal expansion – a technique commonly used for assessing anisotropy in nuclear graphites. Finally, we have employed laser-based, ultrasonic-correlation techniques in attempts to quantify aspects of graphite microstructure such as pore size and distribution. Results of these measurements indicate that additional work must be performed to make this ultrasonic approach viable for quantitative microstructural characterization.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

An analysis of fluff formation in metallic fuel via data analyzes from EBR-II experiments and BISON fuel code modeling

During the operation of EBR-II, it was found that a highly porous structure (over 40% area fraction) formed at the top of several fuel columns. Previous work has shown that this structure, designated fluff in this paper, contains a significant fraction of fuel elements (e.g., U and Pu) which could potentially impact neutronics. This work aims in analyzing the formation mechanism of this microstructure so its impact can be incorporated into future metallic fuel modeling codes and algorithms. This paper details a preliminary examination into the formation mechanisms of fluff by performing qualitative and statistical analysis of EBR-II experimental data. Additionally, the operating conditions that have the greatest impact on fluff formation were determined based on this data set. Also, BISON fuel code simulations were used to help postulate potential fluff formation mechanisms. From this analysis it was found that the largest contributors to fluff formation were fuel burnup and composition, with fluff formation exhibiting a roughly linear positive correlation with increasing burnup and a negative correlation with increasing Pu content. It was also found that higher pin operating temperatures decreased fluff formation but only for U-10Zr fuels.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Mechanisms for stabilizing θ'(Al 2 Cu) precipitates at elevated temperatures investigated with phase field modeling

While most Al–Cu and Al–Si–Cu alloys strengthened by the metastable θ' phase exhibit extensive microstructural degradation above 200 °C, recent experimental work has demonstrated that θ' precipitates can be stabilized to 350 °C by microalloying additions of Mn and Zr, resulting in improved mechanical properties at elevated temperatures. Here, the present work utilizes phase field modeling to study the relationship between microalloying solute elements and the coarsening resistance of θ'. Simulations are designed to parse out the relative influence of various stabilization mechanisms on microstructural evolution of θ' precipitates at elevated temperatures. Specifically, a ternary alloying element is added to a virtual microstructure to study the operation and effectiveness of stabilization mechanisms including solute drag, diffusion barriers, interfacial energy reduction, and lattice strain modification. Simulation results are compared with atom probe tomography observations. Lastly, the simulations rationalize experimental observations of microstructural evolution and solute segregation in Al–Cu–Mn–Zr alloys, and reveal the interlinked thermodynamic and kinetic mechanisms that determine the elevated temperature stability of θ' precipitates.

36 MATERIALS SCIENCE↗

Predicting electrical conductivity in Cu/Nb composites: A combined model-experiment study

The generation of high magnetic fields requires materials with high electric conductivity and good strength properties. Cu/Nb composites are considered to be good candidates for this purpose. In this work, we aim to predict, from theory, the dependence of electric conductivity on the microstructure, most notably on the layer thickness and grain sizes. We also conducted experiments to calibrate and validate our simulations. Bimetal interfaces and grain boundaries are confirmed to have the largest impact on conductivity in this composite material. In this approach, a distribution of the layer thickness is accounted for in order to better model the experimentally observed microstructure. Because layer thicknesses below the mean free path of Cu significantly degrade the conductivity, an average layer thickness larger than expected may be needed to meet conductivity requirements in order to minimize these smaller layers in the distribution. We also investigate the effect of variations in volume fraction of Nb and temperature on the material’s conductivity.

36 MATERIALS SCIENCE↗

ADDITIVE MANUFACTURING OF REFRACTORY ALLOYS

Refractory alloys are known for their high temperature capabilities and are intended for use at ultra-high temperatures above even 1200°C, which exceeds the capabilities of conventional superalloys. Additive manufacturing (AM) is an attractive alternative processing route because refractory alloys are difficult to fabricate through traditional methods; AM can form a near net-shape part with a tailored microstructure. This work seeks to evaluate the solidification behavior of refractory alloys under AM conditions and establish corresponding solidification models. Two binary alloys, Mo30Nb and Nb7.5Ta, as well as the commercial Nb alloy, C103, and one refractory high entropy alloy (RHEA), MoNbTaTi, were subjected to single track melts in a laser powder bed fusion (LPBF) machine. Each melt track was evaluated in the scanning electron microscope (SEM), which determined that some AM conditions used led to non-ideal behavior. Electron backscatter diffraction (EBSD) revealed that the Nb7.5Ta, C103, and MoNbTaTi all exhibited new grain nucleation to various extents while the Mo30Nb exhibited primarily epitaxial growth. This was found to be inconsistent with solidification models that were developed for each alloy and each set of AM conditions to predict the columnar to equiaxed transition behavior (CET) of the experimental microstructures. This disparity was largely attributed to the input parameters for the solidification model, which were developed using Thermo-Calc and SYSWELD. These input parameters include the alloy specific Gibbs-Thomson coefficient and thermophysical properties, the solute specific liquidus slopes and partitioning coefficients, as well as the process specific thermal gradients. Each input parameter was evaluated to determine the likely changes required for the modeled values to generate solidification models that better correspond to what was observed experimentally.

Miklas, Abigail↗

Characterization of Precipitation-Strengthening Heat-Resistant Austenitic Stainless Steels for Life-Prediction Modeling

In this study, the role of minor alloying additions in 347H stainless steels (UNS34709, ASTM A240/240M) on creep-rupture properties at 650-750°C and microstructure evolution during isothermal exposure at 750°C has been investigated, aiming to provide the experimental dataset as boundary conditions of physics-based modeling for material/component life prediction. Four different 347H heats containing various amounts of boron and nitrogen additions were prepared and evaluated. The combined additions of B and N are found to stabilize the strengthening secondary M23C6 carbides and retarding the transition from M23C6 to sigma phase precipitates during thermal exposure. The observed kinetics of microstructure evolution reasonably explains the improvement of creep-rupture properties of 347H stainless steels with the B and N additions.

Yamamoto, Yukinori↗

Influence of microstructure on replacement and porosity generation during experimental dolomitization of limestones

Replacement reactions commonly alter the multiscale pore structures of rocks during fluid-rock interactions. Analysis of these processes in various model fluid-rock systems during controlled laboratory experiments provides insights into the origins of microstructures found in natural materials. This study focused on understanding the effects of initial starting material permeability and resultant differences in transport pathways on porosity and mineralogical changes during limestone dolomitization.A series of replacement experiments (32–317 days in duration) have been conducted in which 1.59 cm (5/8 in.) diameter cores of two different limestones were reacted with saturated MgCl2 solutions at 200 °C. The Texas Cream (Austin Chalk) is a high-porosity, high-permeability limestone, whereas both the porosity and permeability of the Carthage Marble (Burlington Limestone) are relatively low. Altered limestones were imaged using scanning electron microscopy with energy-dispersive X-ray spectroscopy (SEM-EDX), Time-of-Flight Secondary Ion Mass Spectrometry (ToF–SIMS) and electron microprobe analysis (EMPA). A representative grain boundary of the low-porosity limestone was targeted for a focused ion beam (FIB) lift-out and characterized using transmission electron microscopy (TEM). These results were coupled with analyses of radial changes in the porosity distribution of the core derived from X-ray and neutron small- and ultra-small angle scattering ((U)SANS/(U)SAXS).The high-porosity/permeability limestone showed a four times faster bulk replacement rate than the lower-porosity/permeability material, and a different mechanism of porosity development. For the low-porosity limestone, a two-stage replacement occurred, with the reacted region of the core consisting of an inner rim in which the limestone was replaced by two calcite-dolomite solid solutions, and an outer rim in which the dolomite was replaced by magnesite. Elongated pores formed along grain boundaries at the initial limestone/dolomite reaction interface, and additional nanometer-scale porosity was formed at the secondary magnesite replacement rim. Grain boundaries were identified as preferential pathways for transport leading to dolomitization and a grain boundary diffusion rate was calculated based on microstructural characterization. In contrast, replacement in the high-porosity limestone was accompanied by porosity generation through replacement of individual grains by dolomite throughout the sample and, in longer runs, magnesite in outer parts of the core. These observations emphasize that both the mechanisms of the replacement reaction and the microstructure and chemistry of the replaced product are contingent on the initial structure of the starting material.

36 MATERIALS SCIENCE↗

Thermally-Driven Changes to Porosity in TATB-Based High Explosives

Ultra-small- and small-angle neutron scattering techniques were employed to quantify thermally driven changes to the microstructure of the TATB-based composite high explosive, PBX 9502. Samples of PBX 9502 were studied in-situ at temperatures ranging from 25 to 220 °C and after re-equilibration at ambient temperature. Significant changes to the void size and morphology within the PBX 9502 microstructure were observed upon heating and are consistent with the known increase in the shock sensitivity of thermally-treated PBX 9502. More extensive microstructural changes were found after the thermally treated samples were re-equilibrated at ambient temperature. Utilizing a model of ramified porosity, the size and the volume and surface dimensions of voids in the PBX 9502 microstructure were quantified as a function of temperature. The temperature dependence of the void radius of gyration is well correlated with the known increase in the shock sensitivity of PBX 9502 with increasing temperature, providing a microstructural origin for the increased shock sensitivity of PBX 9502 at elevated temperatures.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

Cellular Automaton Modeling of Dynamic Recrystallization of Nimonic 80A Superalloy Based on Inhomogeneous Distribution of Dislocations Inside Grains

A modified cellular automaton (CA) model in the time and space scale is developed to simulate the dynamic recrystallization (DRX) mechanism of Nimonic 80A nickel-base superalloy during hot deformation. Some necessary thermo-mechanical parameters used as input data in CA approach such as work hardening and softening coefficient are fitted according to the previous hot compression experiments. Based on the experimental results, nucleation kinetics is modified as a function of Zener-Holloman parameter. A dislocation density model at transient recrystallization boundary is proposed, in which the dislocation density is a function of temperature, strain rate and annealed dislocation density. The simulated results are in good agreement with experimental results, proving that the modified CA model is capable of predicting both flow behavior and microstructural evolution of Nimonic 80A during hot deformation. According to the experimental and simulated results, the DRX behavior is discussed in detail. It demonstrates that the flow stress and microstructural evolution of DRX have a relationship with the deformation temperature and strain rate.

36 MATERIALS SCIENCE↗

Characterization and Integrated Fabrication of Al Components with Thick TiC{sub p}/Al Composite Coatings via Self-Propagating Reaction

A novel and quick process combining self-propagating reaction with vacuum-expendable pattern casting is presented to accomplish integrated preparation of millimeter-thick TiC{sub p}/Al composite coatings on the Al substrate. Titanium and graphite powders were mixed with the polytetrafluoroethylene (PTFE) additive and pasted on the expendable polystyrene (EPS) followed by compaction. Al components with in situ TiC{sub p}/Al composite coating were simultaneously synthesized at a relatively low temperature of molten Al, which was poured into the assembly of EPS and powder compact inside the silica sands. Differential scanning calorimetry, x-ray diffraction, scanning electron microscopy with energy-dispersive spectroscopy and transmission electron microscopy were used to systematically investigate the thermodynamic characteristics of the reaction, the phase constituents, microstructure and tribological properties of the coatings. The infiltration model describing the densification of the reaction coatings was also developed for the critical wetting condition. The wear characteristics were assessed using a pin-on-disk tribometer with various loads. Results showed that uniform TiC particles stimulated by the PTFE-activated self-propagating reaction afforded superior mechanical properties and wear resistance.

36 MATERIALS SCIENCE↗

Mechanism-based modeling of solute strengthening: Application to thermal creep in Zr alloy

In this paper, a crystallographic thermal creep model is proposed for Zr alloys that accounts for the hardening contribution of solutes via their time-dependent pinning effect on dislocations. The core-diffusion model proposed by Soare and Curtin (2008a) is coupled with a recently proposed constitutive modeling framework (Wang et al., 2017, 2016) accounting for the heterogeneous distribution of internal stresses within grains. The Coble creep mechanism is also included. This model is, in turn, embedded in the effective medium crystallographic VPSC framework and used to predict creep strain evolution of polycrystals under different temperature and stress conditions. The simulation results reproduce the experimental creep data for Zircaloy-4 and the transition between the low (n~1), intermediate (n~4) and high (n~9) power law creep regimes. This is achieved through the dependence on local aging time of the solute-dislocation binding energy. The anomalies in strain rate sensitivity (SRS) are discussed in terms of core-diffusion effects on dislocation junction strength. The mechanism-based model captures the primary and secondary creep regimes results reported by Kombaiah and Murty (2015a, 2015b) for a comprehensive set of testing conditions covering the 500–600 °C interval, stresses spanning 14–156 MPa, and steady state creep rates varying between 1.5·10 -9 s -1 to 2·10 -3 s -1 . There are two major advantages to this model with respect to more empirical ones used as constitutive laws for describing thermal creep of cladding: 1) specific dependences on the nature of solutes and their concentrations are explicitly accounted for; 2) accident conditions in reactors, such as RIA and LOCA, usually take place in short times, and deformation takes place in the primary, not the steady-state creep stage. Finally, as a consequence, a model that accounts for the evolution with time of microstructure is more reliable for this kind of simulation.

36 MATERIALS SCIENCE↗

Chromium-doped uranium dioxide fuels: A review

UO 2 doped with parts per million CR 2 O 3 powder is considered a potential near term accident tolerant fuel candidate. Here, the results of decades of industry and academic research into Cr-doped UO 2 are analyzed and their shortcomings are critiqued. Focusing on the incorporation mechanisms of Cr into the fuel matrix, we explore a mechanistic understanding of the characteristic properties of Cr-doped UO 2 , notably, enhanced fission gas retention attributed to enlarged grain sizes following sintering, along with marginal improvements in the thermophysical properties. The findings of recent X-ray Adsorption Near Edge Spectroscopy studies were compared and put into conversation with historic data regarding the incorporation of Cr in UO 2 . On the basis of defect mechanisms, the case is made for the substitutional incorporation of Cr governing the lattice solubility but not the enhanced U diffusivity. Instead, Cr/CR 2 O 3 redox chemistry in a well-defined oxygen potential explains the differences in the U diffusivity and O/M ratio. The primary mechanism of doping enhanced grain growth is found to be liquid assisted sintering due to a CRO (1) eutectic phase at the grain boundaries. The role of inhomogeneities in Cr concentration in UO 2 at various length scales across the materials microstructure is highlighted and connected to promising experimental and modeling work to fill in the gaps in the current understanding of Cr-doped UO 2 . The review considers both the open scientific questions and engineering applications to illustrate the deep connections between the practice and theory in the design of accident tolerant nuclear fuels. In conclusion, the review ends with an outline of future works that combine meticulous irradiation studies and high resolution experiments with next generation modeling and simulations techniques empowered by machine learning advances to accelerate the fabrication and adoption of Cr-doped UO 2 light water reactors.

Cleveland, Mack Wesley [Massachusetts Inst. of Tec↗

A novel sub-pilot-scale direct-contact ultrasonic dehydration technology for sustainable production of distillers dried grains (DDG)

DDG is a major source of protein, calcium, phosphorus, and sulfur is arguably the most important byproduct of the bioethanol industry with increasing demand over the past few years. Reducing energy consumption in the DDG production process and energy recovery from DDG is vital for sustainable bioethanol productions. In this paper, a novel direct-contact multi-frequency, multimode, and modulated (MMM) ultrasonic dryer (US) was developed for the first time and has been applied in dehydration of wet distillers' grain (WDG). Ultrasonic drying (US) was combined with a convective airflow (HA) at different temperatures of 25 (room temperature), 50 and 70 °C to evaluate the impact of US, HA, and US + HA on drying kinetics, activation energy, chemical compositions, microstructure, and color of DDG. Semi-empirical kinetic models were developed and evaluating drying performances showed that the application of ultrasound significantly enhanced the drying rate and decreased the drying time (by 46%), especially at low drying temperatures. The activation energy for moisture removal in the presence of ultrasound was about 50% of that without ultrasound. The final dried distillers' grains product processed by ultrasonic drying had a brighter color, a higher available protein, a higher digestible protein (the lowest acid detergent insoluble crude protein), and a better surface profile with no compromise on minerals and fiber contents.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Mechanism-based modeling of solute strengthening: application to thermal creep in Zr alloy

This report focuses on the development of a physics-based thermal creep model aiming to predict the behavior of Zr alloy under reactor accident condition. The current models used for this kind of simulations are mostly empirical in nature, based generally on fits to the experimental steady-state creep rates under different temperature and stress conditions, which has the following limitations. First, reactor accident conditions, such as RIA and LOCA, usually take place in short times and involve only the primary, not the steady-state creep behavior stage. Moreover, the empirical models cannot cover the conditions from normal operation to accident environments. For example, Kombaiah and Murty [1,2] recently reported a transition between the low (n~4) and high (n~9) power law creep regimes in Zr alloys depending on the applied stress. Capturing such a behavior requires an accurate description of the mechanisms involved in the process. Therefore, a mechanism-based model that accounts for the evolution with time of microstructure is more appropriate and reliable for this kind of simulation.

36 MATERIALS SCIENCE↗

Final Project Report CFA-14-6357: A New Paradigm for Understanding Multiphase Ceramic Waste Form Performance

This project fabricated model multiphase ceramic waste forms with processing-controlled microstructures followed by advanced characterization with synchrotron and electron microscopy-based 3D tomography to provide elemental and chemical state-specific information resulting in compositional phase maps of ceramic composites. Details of 3D microstructural features were incorporated into computer-based simulations using durability data for individual constituent phases as inputs in order to predict the performance of multiphase waste forms with varying microstructure and phase connectivity.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Protocol-dependent frictional granular jamming simulations: cyclical, compression, and expansion

Granular matter takes many paths to pack in natural and industrial processes. The path influences the packing microstructure, particularly for frictional grains. We perform discrete element modeling simulations of different paths to construct packings of frictional spheres. Specifically, we explore four stress-controlled protocols implementing packing expansions and compressions in various combinations thereof. We characterize the eventual packed states through their dependence of the packing fraction and coordination number on packing pressure, identifying non-monotonicities with pressure that correlate with the fraction of frictional contacts. These stress-controlled, bulk-like particle simulations access very low-pressure packings, namely, the marginally stable limit, and demonstrate the strong protocol dependence of frictional granular matter.

36 MATERIALS SCIENCE↗

Effect of polymer properties and adherend surfaces on adhesion

High temperature polymer surface characteristics associated with joint strength were evaluated. Selected samples represented composite adherends, aluminum filler and fiber glass carrier cloth. Detailed analysis of fractured joint surfaces revealed unique characteristics typical of the specific adhesive formulations and test conditions. A fracture mechanism model was developed for correlating macroscopic shear strength and microstructure of fracture surfaces. Applications were made to unpublished data on polyimides and fluoropolymers.

Dwight, D. W.↗

Thermal Barrier Coatings. Abstracts and figures

The Thermal Barrier Coatings Workshop was held May 21 and 22, 1985, at the NASA Lewis Research Center in Cleveland, Ohio. Six sessions covered Failure Mechanisms and Life Modeling, Effects of Oxidation and Creep, Phase Stability and Microstructural Aspects, Nondestructive and Analytical Assessment, Coating Development, and Alternative Applications.

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