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At least 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Carbon sequestration of steel slag and carbonation for activating RO phase

Carbonation of Ca/Mg minerals in industrial alkaline residues is a technology to sequester CO{sub 2} and reduce its emissions to the atmosphere. In this work, BSE-EDS were used to determine the mineral phase in steel slag; compositions of RO phase were identified and simulated. The carbon sequestration of steel slag was studied, and RO phase was activated by carbonation. Result shows that the amount of CO{sub 2} sequestered in steel slag and RO phase increases as carbonation time increases. Under autoclaving condition, the hydration ratio of MgO in RO phase was 20.10%. Through carbonation, up to 58.83% of MgO in RO phase can be converted into MgCO{sub 3}, and the activation of RO phase by carbonation was manifested. The mechanical properties and volume stability of carbonated steel slag were improved, proving that the positive effect of carbonation on steel slag when applied in cement and cementitious materials.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Process control-enabled mitigation of microstructural and plastic heterogeneities in additively manufactured Grade 91 steel

Synergizing wire arc-directed energy deposition (WA-DED) additive manufacturing (AM) with particle-strengthened creep strength-enhanced ferritic (CSEF) steels enables fabrication and repair of critical power-plant components. Investigations focused on fusion-welded particle-strengthened CSEF steels, such as Grade 91 steel, have linked microstructurally heterogeneous regions—forming due to heat affected zones (HAZ)—with premature failure during elevated temperature service. Fusion-based AM, including WA-DED, likewise generates microstructurally and plastically heterogeneous regions due to spatiotemporally varying thermokinetics during deposition. However, works investigating such microstructural heterogeneities, their implications for mechanical behavior, and strategies to mitigate their formation remain scarce. This work identifies microstructurally and plastically heterogeneous regions within the WA-DED-processed Grade 91 steel. Spatial microhardness variations in the as-fabricated specimen correlate with the variation in the attributes of grain, martensitic microstructure, and precipitates across the fusion zone and HAZ. Digital image correlation-enabled tensile tests performed at 500 °C revealed pronounced deformation localization and a wave-like strain distribution, with wavelength close to the melt pool depth, indicating susceptibility of the as-fabricated components to premature creep failure. Such heterogeneity in microstructural and mechanical behavior was attributed to recurring solid-state phase transformations. Subsequently, an interlayer temperature control strategy was implemented, wherein maintaining interlayer temperature above the martensitic start temperature mitigated the heterogeneous microstructural and plastic response in the as-fabricated condition. Findings open pathways to achieving deformation-localization- and creep-resistant microstructures in WA-DED fabricated particle-strengthened CSEF steel components, reducing reliance on post-welding heat treatments—conventionally required to enhance creep resistance—and enabling on-demand, short lead-time fabrication of next-generation power-plant components.

Heat affected zones↗
DOE OSTI2022

Carburization and decarburization behavior of Grade 91 ferritic-martensitic steel in liquid sodium environments

Here, this paper presents a study of carbon transfer and its effect on microstructure and tensile properties of Grade 91 (G91) ferritic-martensitic steel exposed to sodium at 550–650 °C. Sodium exposure tests were conducted in Argonne's forced convection sodium loops up to exposure times of ~40,000 h. Thermal aging study of G91 steel was conducted in parallel to isolate the thermal aging effect from the sodium effect. It was found that sodium exposures at 650 °C dissolved M 23 C 6 carbides, eliminated the martensite subgrain structure resulting in excessive grain growth and reduced the tensile strength by >50%, while sodium exposures at 550 and 600 °C had an insignificant effect on its microstructure and tensile properties. These effects were attributed to the carburization/decarburization process of G91 steel in sodium environments. Carbon concentrations in sodium were determined by a foil equilibration method. The estimated carbon concentration was in the range of 0.8–1.2 ppm in the SMT-1 loop and 0.3–0.7 ppm in the SMT-2 loop. Thermodynamic analysis of the carburization – decarburization process was conducted for G91 steels exposed in sodium environments. The carbon activity-concentration relationship for G91 was evaluated by considering four phases in G91, i.e. bcc ferrite, M 23 C 6 , NbC and VC carbides. It was found that the carburization-decarburization process in G91 steel was dictated by M 23 C 6 carbides at high carbon activities, while NbC and VC carbides dominated the process at low carbon activities. The calculated carburization-decarburization boundary showed that G91 would undergo decarburization at 650 °C and carburization at 550 °C in the sodium loop environments, which was consistent with our experimental observations. This experimental and theoretical analysis provided a basis for predicting the effect of carbon transfer on the integrity of reactor components in sodium environments and for the design of new alloys used in sodium-cooled fast reactors.

36 MATERIALS SCIENCE↗
DOE OSTI2023

The effect of phosphorus on precipitation in irradiated reactor pressure vessel (RPV) steels

Embrittlement of light water reactor pressure vessels (RPV) steels by fast neutron irradiation may limit extended nuclear plant life. Embrittlement, which is manifested as increases in various indexes of a ductile to brittle transition temperatures (ΔT), is primarily due to hardening by nanoscale precipitates containing Cu, Ni, Mn, and Si, which form under irradiation. In addition to these elements, P has also been found to play a role in embrittlement. While only slightly enriched in the precipitates, hardening and embrittlement increase with trace P concentrations in low-Cu steels. Here, we characterize the individual and synergistic irradiation precipitation and hardening mechanisms in a series of RPV steels containing no to low-Cu and with systematic variations in Ni and P. In this study, the steels were irradiated to a fluence of ~ 1.38 x 10 20 n/cm 2 at ~ 292 °C in the UCSB ATR-2 experiment. In Cu-free medium and high-Ni RPV steels, atom probe tomography shows that P and Ni promotes precipitation of P-Mn-Si-Ni and Mn-Si-Ni precipitates, respectively. The precipitate microstructure correlates with the observed irradiation hardening.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Understanding the effect of minor alloying elements on helium bubble formation in ferritic-martensitic steels

Ferritic-martensitic steels are promising structural materials for advanced nuclear reactors. To minimize long-term radioactivity, reduced-activation ferritic-martensitic steels have been developed by substituting high-activation elements like Ni and Mo with low-activation elements such as W. However, the impact of these alloying modifications on helium bubble formation, which plays a key role in material swelling, remains unclear. Here, in this study, we compared helium bubble formation in ferritic-martensitic steel T91 and reduced-activation ferritic-martensitic steel F82H. Both materials were irradiated with sequential 100 keV, 150 keV, and 200 keV helium ions to a dose of 0.5 dpa and a helium concentration of 9,000 appm at 500°C. The helium bubbles in F82H exhibited a larger average size and a lower density than those in T91, suggesting differences in minor alloying elements may influence the bubble growth. Here, to investigate the effects of these alloying elements, we characterized radiation-induced segregation near bubbles and grain boundaries. Prominent Ni-Mn-Si enriched clusters were found near bubbles in T91, while only Mn-Si enriched clusters were found near bubbles in F82H. In addition, the obvious Cr enrichment near grain boundaries was absent around bubbles in both steels. The different segregation trends among elements revealed the variations in element diffusion mechanisms and the different sink biases between bubbles and grain boundaries. Cr enrichment near grain boundaries is mostly driven by interstitial-mediated diffusion. However, since bubble growth relies on net vacancy flux, vacancy-mediated diffusion plays a dominant role in controlling element segregation near bubbles. Therefore, Cr enrichment was not found near bubbles. Because of preferential vacancy-drag diffusion for Ni, Si and Mn, these elements were enriched near bubbles. Due to the strong binding energies of vacancies with these solute atoms, the vacancy diffusivity can be reduced near these solutes. Therefore, the more prominent Ni-Si-Mn clustered near helium bubbles in T91 lead to stronger suppression of helium bubble growth compared to F82H.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Additive manufacturing as a processing route for steel-aluminum bimetallic structures

Here we present results on the fabrication of steel-aluminum bi-metallic structures using directed energy deposition additive manufacturing. The challenges associated with the fabrication of a sharp transition from steel to aluminum are uncovered using ex-situ characterization techniques and thermo-mechanical modeling of the deposition process. It was found that the fabrication of a sharp steel-aluminum transition is challenging with extensive cracking observed at the interface. The cracking was attributed to the combined effect of residual stress development due to thermal expansion coefficient mismatch and the presence of ordered intermetallics with low ductility at the interface. Using a coupled thermodynamic and thermo-mechanical modeling approach, potential pathways to enable the fabrication of steel-aluminum bi-metallic structures using additive manufacturing are proposed. The results presented here can lay the foundation for future work on the fabrication of bi-metallic steel-aluminum structures using directed energy deposition.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Optimization of direct aging temperature of Ti free grade 300 maraging steel manufactured using laser powder bed fusion (LPBF)

Maraging steels are of interest to the tool and die industry owing to their high strength, toughness and machinability. Additive manufacturing technologies like laser powder bed fusion (LPBF) can result in a paradigm shift in the design of maraging steel tools. Here, the lack of precipitates, in combination with solute segregation and non-equilibrium microstructure in Grade 300 maraging steel fabricated via LPBF makes the steel amenable to strengthening via direct aging post fabrication instead of the conventional solution treatment and aging. In this study we have focused on optimizing the direct aging temperature for a Ti-free Grade 300 maraging steel fabricated via LPBF for two different aging times. Through strain hardening analysis and detailed microstructural characterization, we show that direct aging at a temperature of 440 °C for 6 h resulted in the best strength-ductility combination. Aging samples at a lower temperature or shorter time resulted in no strain hardening prior to necking as a result of lower fraction of reverted austenite, whereas aging samples at a higher temperature resulted in extensive recrystallization of martensite, coarsening of precipitates, and extensive austenite reversion, resulting in softening of the fabricated parts.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Effect of Cr and Ni concentrations on resilience of cast Nb- alloyed heat resistant austenitic steels at extreme high temperatures

Austenitic Cr–Ni alloyed heat resistant steels with Nb additions are used for intensively thermo-mechanically loaded cast components working in extreme high temperature oxidizing environment. Their performance during static oxidation and transient thermo-mechanical loading was investigated to recommend an optimal cost-effective Cr/Ni composition of Nb-alloyed austenitic class steels. Here, the static oxidation and transient thermo-mechanical behavior of three austenitic steels with different Cr/Ni alloying levels were investigated and compared for variety of working conditions. Static oxidation was performed between 900 °C and 1000 °C in air for 400 h. The critical temperature which increases spallation during static oxidation was determined for each of the steel alloying levels. In addition, thermal cycling of a constrained specimen was done with varying upper cycling temperatures between 850 °C and 1000 °C. SEM and TEM analyses were supported by thermodynamic simulation of the phases precipitated in the metal matrix and the structure of formed oxide layers. These studies were used to determine the mechanisms of degradation of thermo-mechanically loaded Cr/Ni austenitic steels at extreme high temperatures. A recommendation for a cost-effective Cr/Ni alloying level for different working conditions was determined.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Effect of impurities on phase transformation and precipitation in a low-carbon steel

Impurity elements have been added to a commercial low carbon steel grade to simulate the levels that could arise as a result of increased scrap recycling during steel production. In this study, continuous cooling transformation (CCT) diagrams were constructed for the steels with varying levels of impurities, and it is shown that impurities suppress the phase transformation across a wide range of cooling rates. It was found that a step was formed in the start temperature curve, separating the reconstructive and displacive transformations. The influence of impurities on both the reconstructive transformation and displacive transformation are discussed. Additionally, Cu precipitates were observed using scanning transmission electron microscopy (STEM) in the highest impurity-containing steel after slow cooling (0.05°C/s), fast cooling (5°C/s) and interrupted cooling. It was found that the precipitation kinetics is in the following order: cementite within the secondary phase and cementite at secondary phase-ferrite interface> ferrite grain boundaries> ferrite grain matrix. Atom-probe tomography (APT) revealed Cu precipitates formed on the surface of cementite lamellae, but not within it. This work offers insights for the phase transformation control and precipitation regulation during the thermomechanical processing of low carbon steels containing impurity elements due to scrap recycling.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Effects of processing temperature on the corrosion and tribocorrosion resistance of perhydropolysilazane-derived coatings on AISI 304 steel

Ensuring a highly corrosion and erosion resistant surface is critical to the reliability and structural integrity of steel canisters for long-term nuclear waste storage in corrosive environments. In this work, perhydropolysilazane (PHPS)-derived coating has been successfully applied to enhance the pitting and tribocorrosion resistance of 304 stainless steels in 0.6 M NaCl solution. Two types of coatings were synthesized on the stainless steel substrate by crosslinking PHPS at room temperature or 600 °C, resulting in different mechanical and corrosion performance. Further, Raman spectra revealed that Si-O bonds were generated in the coating crosslinked at room temperature after corrosion, while absent in that pyrolyzed at 600 °C. In tribocorrosion tests, both coatings were protective to the steel substrate, with the protective effect being more pronounced in the 600 °C pyrolyzed coating. Overall, the PHPS-derived coating synthesized at 600 °C exhibited better protection for steel in wear and corrosion coexisting environments than those synthesized at room temperature.

36 MATERIALS SCIENCE↗
DOE OSTI2022

High-Temperature RF Transmission Loss Characteristics of Platinum–Inconel 600 and Platinum–304 Steel Interconnects

Radio frequency (RF) transmission losses that occur at electronic interconnects is currently an important limitation of wireless sensors and other electronic device packages that must operate in high-temperature environments. Herein, in-situ RF transmission losses were measured for two types of interconnects: platinum (Pt) wire bonded to an Inconel 600 coaxial cable; and Pt-wire bonded to a block of 304 steel. Heating the Pt wire/Inconel interconnects at 800 °C for up to 200 hours were found to be very stable with no measurable transmission losses. In contrast, Pt wire/304 steel block interconnects examined over similar test periods at 800 °C exhibited gradual increases in transmission losses leveling off at 10, 38 and 85 mdB at 400 MHz, 700 MHz, and 1 GHz, respectively. Increasing the test temperature to 900 °C caused further elevated transmission losses of 30, 70 and 108 mdB at the same reported frequencies. By comparison, temperature cycling of the Pt wire/304 steel interconnects between room temperature and 900 °C was found to cause more significant degradation. In particular, four thermal cycles from room temperature to 900 °C resulted in losses of 75, 271, and 482 mdB at the same reported frequencies. Parabolic oxidation relative to the RF skin depth in the 304 steel block at the tested frequencies are discussed as possible reasons for the transmission losses during the isothermal soaks, whereas interconnect degradation due to differences in thermal expansion between Pt and 304 steel are primarily responsible for transmission losses caused by high temperature cycling.

304 steel↗
DOE OSTI2025

Tailoring composition and deformation modes at the microstructural level for next generation low-cost high-strength austenitic stainless steels

The objective of this project is to enable deliberate development of cost-effective, hydrogen resistant alloys by establishing detailed relationships specific to the effects of alloy composition, short-range order (SRO), and microsegregation in the presence of hydrogen on the transition between homogeneous deformation and localized plasticity in shear bands. In collaboration with the International Institute for Carbon-Neutral Energy Research, I2CNER, at Kyushu University in Japan, we conceptualized, designed, and manufactured four austenitic alloys that maintain corrosion resistance and ensure lower cost relative to baseline commercial alloys. The mechanical properties and deformation modes of the novel alloys (KU alloys) were assessed in the presence of hydrogen (H). Correlations between composition and performance revealed that two of the KU alloys are suitable replacements for 316 steel, while another is a viable replacement for 304 steel at room temperature. We found that, in the presence of other austenite stabilizing elements namely Mn and N, replacing Ni with Cu does not lead to martensite formation as has been previously reported.1–3 Furthermore, we found that the addition of Cu leads to an earlier onset of multiple slip resulting in an relative earlier onset of a higher work hardening rate (WHR). Greater understanding of the relationships between alloy composition and SRO required the development of a novel advanced electron diffraction methodology to characterize SRO in complex FCC alloys. This innovative approach, which combines fluctuation and correlation analyses of diffuse-scattering signals, successfully differentiated between SRO and long-range ordering (LRO). Further investigations into annealed austenitic stainless steels could provide insights into manipulating SRO and its effects on material properties. Atomistic simulations provided understanding of SRO behavior that was difficult to capture experimentally. This project created the first spin cluster expansion model that is able to capture and describe SRO effects in Fe-Ni-Cr FCC alloys, accounting for the non-negligible effects of magnetism. An automated computational workflow was established to provide reliable predictions of SRO in Fe-Ni-Cr austenitic alloys, both with and without the presence of H atoms. Analysis of the propensity for SRO in Fe-Ni-Cr alloys revealed that H tends to cluster with specific, well-defined SRO domains. The computational framework is general purpose and can be extended to realistic stainless steels across diverse composition ranges. With confidence that SRO is possible in austenitic stainless steels, we developed a discrete dislocation finite element code to understand the interaction of dislocations with SRO in the presence of H. By incorporating H effects on the dislocation emission and SRO stress field we show that the critical stress for the dislocation pileup to breakthrough the SRO domain decreases in the presence of H, which directly contributes localized deformation at the macroscale. Through the simulation of a uniaxial tension test, we demonstrated that H-induced weakening of SRO stress field and H-enhanced dislocation emission can lead to the onset of shear localization at lower macroscopic strains. As a whole, this project identified three novel alloys that show improvements in performance and cost efficiency for H-facing applications by studying correlations between alloy chemistry and deformation behavior. We also made significant advancements to experimental and computational methodologies necessary to study the chemistry and distribution of SRO across a range of alloys, which in turn allowed us to demonstrate how deformation mechanisms change due to the contributions of SRO in austenitic alloys in the presence of H. The combined advancements in fundamental understanding with novel alloy development in this project has increased the viability of next generation H-technologies for the broader public through accessible low-cost alloys and accelerated development towards future H-infrastructure.

08 HYDROGEN↗
DOE OSTI2025

Laser Powder Directed Energy Deposition of Steels for Nuclear Applications

This comprehensive investigation examines the structure–property relationships in two nuclear alloy systems—Alloy 709 (A709) austenitic stainless steel and Grade 92 (G-92) ferritic/martensitic (F/M) steel—manufactured via directed energy deposition (DED) for sodium-cooled fast reactor applications. This study establishes the fundamental mechanisms for controlling microstructures for optimizing the mechanical performance of additively manufactured nuclear materials through systematic heat treatment optimization and multiscale characterization. As-deposited A709 steel develops a complex multiscale strengthening architecture consisting of a fine cellular solidification structure with diameter of 2-3 µm within10–50 µm grains, elevated dislocation densities from rapid thermal cycling, and grain boundary precipitates that activate concurrent Hall–Petch, dislocation, and precipitation hardening mechanisms to achieve exceptional properties [yield strength (YS): 603 MPa, ultimate tensile strength (UTS): 844 MPa, Vickers hardness: 220 HV] that achieve a 44% superior strength compared to that of the wrought material. Heat treatments produce different results. Solution annealing (SA) dissolves the cellular structure and reduces the hardness to 190 HV. Precipitation treatment (PT) keeps the cellular structure but adds carbides, allowing the hardness to reach 205 HV. The best approach combines both treatments (SA+PT) and creates uniform precipitate distributions with M 23 C 6 carbides at the grain boundaries and MX carbonitrides in the matrix, achieving a hardness of 195 HV. However, directional differences persist, with a 12%–15% strength variation between orientations due to the inherited layered microstructural architecture that survives aggressive heat treatment. While tensile testing at 550°C demonstrates 40%–50% thermal softening with dynamic strain aging, DED A709 steel still maintains a 71% higher YS than that of the wrought material. Ion irradiation studies (100–400 dpa) of DED A709 steel reveal progressive radiation damage with increasing void density and radiation-induced segregation causing nickel enrichment and chromium depletion, which will ultimately compromise mechanical properties. As-deposited G-92 exhibits exceptional strength (UTS: 1650–1700 MPa, 430 HV) through a complex microstructure containing both ferrite and martensite phases, a high geometrically necessary dislocation (GND) density (17.04×10 14 /m 2 ), and fine carbides. Heat treatments create distinct changes. Normalizing produces fresh martensite with the highest hardness (460 HV) and an increased GND density (20.23×10 14 /m 2 ). Tempering develops dual precipitation systems and reduces the hardness to 290 HV. The optimal approach uses sequential normalizing plus tempering, achieving balanced properties with the lowest hardness (250 HV) and a reduced GND density (11.01×10 14 /m 2 ). A processing-dependent anisotropy is observed: horizontal specimens achieve superior ductile behavior, while vertical specimens exhibit brittle failure. A tempering heat treatment successfully mitigates this anisotropic behavior by transforming the hard martensitic as-deposited structure into tempered martensite enabling both horizontal and vertical specimens to exhibit similar stress–strain characteristics with visible necking behavior. Remarkably, testing at 550°C reveals a reversal in the anisotropy, where as-deposited specimens achieve near isotropy with superior thermal stability (a 15%–20% strength reduction), while tempered specimens develop an orientation dependence with a 25%–30% strength reduction. Both alloy systems demonstrate that DED processing creates specimens with a superior strength through refined microstructural features, though with distinct strengthening mechanisms—austenitic through cellular structures and precipitates versus F/M through phase transformations and precipitates. Heat treatment optimization requires alloy-specific approaches, with A709 benefiting from controlled precipitation while G-92 requires careful phase transformation control. The results show that DED manufacturing can produce nuclear materials with exceptional performance, but directional effects and temperature-dependent behavior must be carefully considered for reactor component design and qualification.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

Evidence for carbon dioxide removal via enhanced rock weathering with steel slag, though not basalt, in a midwestern U.S. field trial

Enhanced weathering is an emergent pathway for permanent atmospheric carbon dioxide removal (CDR). However, despite a dramatic increase in academic and commercial research, there remain relatively few published examples of field evidence demonstrating the effectiveness of enhanced weathering. Here, we present results from a three-year field trial that evaluated steel slag and crushed basalt applied as amendments in a conventional agricultural system in the Midwestern United States. Steel slag applied to initially acidic soil increased porewater pH and alkalinity and increased soil pH and Ca-saturation. Together, changes in porewater chemistry and soil properties provide strong evidence for steel slag weathering and CDR. However, steel slag applied to soils with a neutral initial pH did not generate significant changes in soil or porewater chemistry. In addition, coarse-grained crushed basalt did not generate significant change in any of the soils. Strong acid effects were apparent in all 3 years of monitoring soil porewater chemistry. Overall, our results demonstrate clear evidence of CDR from applying steel slag amendments to acidic cropland soils while also highlighting the difficulty of greenhouse gas reduction accounting from enhanced weathering and the variable outcomes that can occur depending on feedstock and soil type.

Geosciences↗
DOE OSTI2023

Characterization and Electrochemical Analysis of Acidic Condensate-Induced Corrosion on Aluminized Coating on Steel in Residential Heaters

Condensing furnace residential heaters are starting to replace outdated and less efficient non-condensing units in homes across the US. However, the burning of natural gas in these new units produces acidic gases, which can form acid droplets (H 2 SO 4 , HNO 3 , H 2 CO 3 , etc.) that are corrosive to low-grade heat exchanger metallic materials. Type-1 aluminized steel has been used in industrial applications, such as marine, heating, and automobile parts, due to its resistance to oxidation at elevated temperature. Many components of the condensing furnaces, including heat exchangers, are made from type-1 aluminized steel. We investigated the interaction of type-1 aluminized steel substrates with two acidic condensate liquids by 500 h corrosion exposures as well as short-term electrochemical impedance measurements. SEM plan and cross-sectional view images revealed damage to the Al-Si rich layer and exposure of the steel substrate. The non-uniform damage in the Al-Si rich layer was likely attributed to a pitting corrosion mechanism and induced by high acidity of the condensate liquid. Electrochemical impedance measurements in an acidic condensate revealed lower corrosion resistance of the aluminized steel surface with a weld line, identifying welded sections as preferential corrosion initiation sites.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Thermomechanical Processing for Improved Mechanical Properties of HT9 Steels

Thermomechanical processing (TMP) of ferritic–martensitic (FM) steels, such as HT9 (Fe–12Cr–1MoWV) steels, involves normalizing, quenching, and tempering to create a microstructure of fine ferritic/martensitic laths with carbide precipitates. HT9 steels are used in fast reactor core components due to their high-temperature strength and resistance to irradiation damage. However, traditional TMP methods for these steels often result in performance limitations under irradiation, including embrittlement at low temperatures (<~430 °C), insufficient strength and toughness at higher temperatures (>500 °C), and void swelling after high-dose irradiation (>200 dpa). This research aimed to enhance both fracture toughness and strength at high temperatures by creating a quenched and tempered martensitic structure with ultrafine laths and precipitates through rapid quenching and unconventional tempering. Mechanical testing revealed significant variations in strength and fracture toughness depending on the processing route, particularly the tempering conditions. Tailored TMP approaches, combining rapid quenching with limited tempering, elevated strength to levels comparable to nano-oxide strengthened ferritic alloys while preserving fracture toughness. For optimal properties in high-Cr steels for future reactor applications, this study recommends a modified tempering treatment, i.e., post-quench annealing at 500 °C or 600 °C for 1 h, possibly followed by a brief tempering at a slightly higher temperature.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Cost and Life Cycle Analysis for Deep CO 2 Emissions Reduction for Steel Making: Direct Reduced Iron Technologies

Among heavy industrial sectors worldwide, the steel industry ranks first in carbon dioxide (CO 2 ) emissions. Technologies that produce direct reduced iron (DRI) enable the industry to reduce emissions or even approach net‐zero CO 2 emissions for steel production. Herein, comprehensive cradle‐to‐gate (CTG) life cycle analysis (LCA) and techno‐economic analysis (TEA) are used to evaluate the CO 2 emissions of three DRI technologies. Compared to the baseline of blast furnace and basic oxygen furnace (BF–BOF) technology for steel making, using natural gas (NG) to produce DRI has the potential to reduce CTG CO 2 emissions by 33%. When 83% or 100% renewable H 2 is used for DRI production, DRI technologies can potentially reduce CO 2 emissions by 57% and 67%, respectively, compared to baseline BF–BOF technology. However, the renewable H 2 application for DRI increases the levelized cost of steel (LCOS). When renewable natural gas (RNG) and clean electricity are used for steel production, the CTG CO 2 emissions of all the DRI technologies can potentially be reduced by more than 90% compared to the baseline BF–BOF technology, although the LCOS depends largely on the cost of RNG and clean electricity.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2020

Perspectives on Quenching and Tempering 4340 Steel

Steels are ubiquitous due to their affordability and the landscape of useful properties that can be generated for engineering applications. But to further expand the performance envelope, one must be able to understand and control microstructure development by alloying and processing. In this paper we use multiscale, advanced characterization to better understand the structural and chemical evolution of AISI 4340 steel after quenching and tempering (Q&T), including the role of quench rate and short-time, isothermal tempering below 573 K (300 °C), with an emphasis on carbide formation. We compare the microstructure and/or property changes produced by conventional tempering to those produced by higher temperature, short-time “rapid” tempering. We underscore that no single characterization technique can fully capture the subtle microstructure changes like carbon redistribution, transition carbide and/or cementite formation, and retained austenite decomposition that occur during Q&T. Only the use of multiple techniques begins to unravel these complexities. After controlled fast or slow quenching, η transition carbides clearly exist in the microstructure, likely associated with autotempering of this high martensite start temperature (Ms) steel. Isothermal tempering below 598 K (325 °C) results in the relief of carbon supersaturation in the martensite, primarily by the formation of η transition carbides that exhibit a range of carbon levels, seemingly without substitutional element partitioning between the carbide and matrix phases. Hägg transition carbide is present between 300 °C and 325 °C. After conventional tempering at or above 598 K (325 °C) for 2 h, cementite is predominant, but small amounts of cementite are also present in other conditions, even after quenching. Previous work has indicated that silicon (Si) and substitutional elements partition between the cementite, which initially forms under paraequilibrium conditions, and the matrix. Phosphorous (P) may also be preferentially located at cementite/matrix interfaces after high temperature tempering. Slower quench rates result in greater amounts of retained austenite compared to those after fast quenching, which we attribute to increased austenite stability resulting from “autopartitioning”. Rapid, high temperature tempering is also found to diminish tempered martensite embrittlement (TME) believed to be associated with the extent of austenite decomposition, resulting in mechanical properties not attainable by conventional tempering, which may have important implications with respect to industrial heat treatment processes like induction tempering. Controlling the amount and stability of retained austenite is not only relevant to the properties of Q&T steels, but also next-generation advanced high strength steels (AHSS) with austenite/martensite mixtures.

36 MATERIALS SCIENCE↗