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All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Final Report on Development of Microwave Resonant Cavity Transducer for Fluid Flow Sensing: Development of Microwave Cavity Flow Meter for Advanced Reactor High Temperature Fluids

We are investigating a microwave resonant cavity transducer for flow sensing in the vessel of a high temperature fluid advanced reactor (AR), such as a molten salt cooled reactor (MSCR) or a sodium fast reactor (SFR). This transducer is a hollow metallic cylindrical cavity, with one of the flat walls of the cylinder flexible enough to undergo microscopic deflection due to dynamic fluid pressure. Membrane deflection leads to a shift in the microwave resonant frequency, which can be detected with a spectrum analyzer. We have developed a continuum electromechanics model of the microwave resonant cavity transducer performance. The deflection of the membrane is calculated using equations from the theory of plates and shells for deflection of radially constrained thin circular disk under uniform load. The microwave frequency shift is calculated using the equations from the microwave cavity perturbation theory. The transducer model was validated with proof-of-concept experimental data of water flow sensing with a Brass 360 right circular cylinder with 22.2mm diameter and 203µm thick wall. The cavity was excited through a subwavelength hole in TE 011 mode with resonant frequency f ≈ 17.8GHz. Subsequently, we have performed a preliminary proof-of-principle test of flow sensing in high temperature liquid sodium in environment. For this test, we have developed a cylindrical resonator with the same dimensions as for the Brass 360 cavity. The resonator for high temperature liquid sodium test was machined from stainless steel 316 and electroplated with silver on the interior surfaces. We have also developed and insertion probe consisting of a 50cm WR-42 brass waveguide enclosed in a protective SS316 tube. The cavity was excited through a subwavelength hole on the side of the wall of the cylinder in the TE 011 mode with resonant frequency f ≈ 17.8GHz. The liquid sodium setup consists of a cylindrical vessel with a center feed line, where a transducer inserted through the top cap of the vessel measures velocity of the impinging liquid jet. The sodium flow sensing study was performed in a liquid sodium vessel at 340°C temperature and ambient pressure. The flow rate was changed by varying sodium pump power, and a frequency shift of several hundred kHz was observed. The transducer was removed after 70 days of testing. No visual damage was observed, and the electromagnetic response remained the same. As a calibration experiment, we have assembled a water vessel with a center feed, and with dimensions similar to those of the liquid sodium setup. Water flow sensing was performed before and after liquid sodium test. The responses in both cases are similar and agree with COMSOL computer simulations. Because long-term (multi-year) experimental tests of transducer resilience to harsh environment are not practical, we have developed a probabilistic model of creep to estimate transducer resilience to the harsh environment. The probabilistic model considers diffusion creep under the condition of high temperature and low stress, where the stress and temperature are allowed to be random variables with Gaussian distributions. Using the probabilistic model, we estimate inelastic membrane deflections due to creep for several temperature ranges. We conclude that for temperatures less than 650°C, creep has negligible long-term effect on the transducer performance.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Fabrication and Testing of Solid-Solution Strengthened Corrosion Resistant Alloys For Service in Molten Fluoride Environments

The demand for higher system thermal efficiencies requires the operation of power generation cycles and heat conversion systems at progressively higher temperatures. As the system operating temperature increases, existing materials may not provide adequate mechanical properties or environmental compatibility or both. There is an increasing commercial interest in the development and deployment of liquid-fueled Molten Salt Reactors (MSRs). Hastelloy®N, the highest performing candidate MSR structural alloy, is not capable of operations at temperatures above 700°C, thus limiting the performance of these systems. Using an Integrated Computational Materials Engineering (ICME)-approach and small laboratory scale heats, ORNL developed a class of patented alloys covered by U.S. Patent 9, 435, 011 B2, “Creep-resistant, Cobalt-free alloys for high temperature, liquid-salt heat exchanger systems,” similar to Hastelloy®N in that they are primarily solid solution strengthened. In contrast to precipitation strengthened alloys, the microstructure of solid solution alloys and hence the high temperature mechanical properties are stable for extended periods of time allowing long reactor operating life. The new alloys have shown to possess good resistance to liquid fluorides at temperatures up to 850°C and have significantly improved creep properties when compared to Hastelloy®N. The purpose of the CRADA project was for ORNL to collaborate with Haynes International- a materials producer, MetalTek International- a foundry, and Kairos Power – an advanced reactor developer – to scale-up selected alloys, evaluate their properties, and identify one solid solution strengthened alloy that can meet the property requirements for the reactor being developed by Kairos Power and other similar liquid fluoride-salt cooled reactors. As part of the project, eight alloys were down-selected and fabricated in larger industrial scale heats by Haynes International. Resistance to molten salt was evaluated in flowing FLiNaK and FLiBe by Kairos Power using their Rotating Cage Loop (RCL) system. Accounting for iron deposition during these tests, the new alloys displayed very low net mass change showing excellent corrosion performance in molten salt. Creep properties evaluated at ORNL were found to be better than that of Hastelloy®N and 316 stainless steel. Long-term stabilities of the alloys evaluated by Haynes International showed that these alloys have excellent thermal stability in the temperature range 704.4-815.6°C, with the change in strength and ductility being less than 10-15% after a 4000-hour exposure at 815.6°C. Autogenously Gas Tungsten Arc Welding (GTAW) welded samples showed less than 10% change in yield strength / ultimate tensile strength / total elongation compared to the basemetal, indicating that the alloys have excellent weldability. Three parts were successfully investment-cast using one alloy with very little voiding showing feasibility of fabricating parts using the casting process. This project enabled extensive interaction between the material producer Haynes International, casting supplier MetalTek, and reactor developer Kairos Power. This facilitated testing of materials and components produced using the newly developed alloys by the end-user. This allowed the generation of critical dataset required for down-selection of a few promising alloys for further development. This data is also currently being shared with other reactor designers for them to evaluate the suitability of this alloy for their reactor design. The availability of this alloy will ultimately enable the design and development and deployment of MSRs with increased temperature of operation and thus, improved efficiencies.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2025

Fabrication and Testing of Solid-Solution Strengthened Corrosion Resistant Alloys For Service in Molten Fluoride Environments

The demand for higher system thermal efficiencies requires the operation of power generation cycles and heat conversion systems at progressively higher temperatures. As the system operating temperature increases, existing materials may not provide adequate mechanical properties or environmental compatibility or both. There is an increasing commercial interest in the development and deployment of liquid-fueled Molten Salt Reactors (MSRs). Hastelloy®N, the highest performing candidate MSR structural alloy, is not capable of operations at temperatures above 700°C, thus limiting the performance of these systems. Using an Integrated Computational Materials Engineering (ICME)-approach and small laboratory scale heats, ORNL developed a class of patented alloys covered by U.S. Patent 9,435,011 B2, “Creep-resistant, Cobalt-free alloys for high temperature, liquid-salt heat exchanger systems,” similar to Hastelloy®N in that they are primarily solid solution strengthened. In contrast to precipitation strengthened alloys, the microstructure of solid solution alloys and hence the high temperature mechanical properties are stable for extended periods of time allowing long reactor operating life. The new alloys have shown to possess good resistance to liquid fluorides at temperatures up to 850°C and have significantly improved creep properties when compared to Hastelloy®N. The purpose of the CRADA project was for ORNL to collaborate with Haynes International- a materials producer, MetalTek International- a foundry, and Kairos Power – an advanced reactor developer – to scale-up selected alloys, evaluate their properties, and identify one solid solution strengthened alloy that can meet the property requirements for the reactor being developed by Kairos Power and other similar liquid fluoride-salt cooled reactors. As part of the project, eight alloys were down-selected and fabricated in larger industrial scale heats by Haynes International. Resistance to molten salt was evaluated in flowing FLiNaK and FLiBe by Kairos Power using their Rotating Cage Loop (RCL) system. Accounting for iron deposition during these tests, the new alloys displayed very low net mass change showing excellent corrosion performance in molten salt. Creep properties evaluated at ORNL were found to be better than that of Hastelloy®N and 316 stainless steel. Long-term stabilities of the alloys evaluated by Haynes International showed that these alloys have excellent thermal stability in the temperature range 704.4-815.6°C, with the change in strength and ductility being less than 10-15% after a 4000-hour exposure at 815.6°C. Autogenously Gas Tungsten Arc Welding (GTAW) welded samples showed less than 10% change in yield strength / ultimate tensile strength / total elongation compared to the basemetal, indicating that the alloys have excellent weldability. Three parts were successfully investment-cast using one alloy with very little voiding showing feasibility of fabricating parts using the casting process. This project enabled extensive interaction between the material producer Haynes International, casting supplier MetalTek, and reactor developer Kairos Power. This facilitated testing of materials and components produced using the newly developed alloys by the end-user. This allowed the generation of critical dataset required for down-selection of a few promising alloys for further development. This data is also currently being shared with other reactor designers for them to evaluate the suitability of this alloy for their reactor design. The availability of this alloy will ultimately enable the design and development and deployment of MSRs with increased temperature of operation and thus, improved efficiencies.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Multiscale and Machine Learning Modeling for Process-informed Microstructure Prediction in Additively Manufactured Materials using MALAMUTE

The Advanced Materials and Manufacturing Technologies (AMMT) program under the Department of Energy Office of Nuclear Energy aims to develop and qualify additively manufactured materials for nuclear applications. One key challenge to this is the microstructural variability observed in the additively manufactured products and their impact on the properties and performance of the material in extreme environments. AMMT is using a combination of high-throughput experimental and modeling techniques to accelerate qualification. Conventionally, in-situ and ex-situ characterizations and testing are performed to correlate different aspects of the additive manufacturing process to the final product and its performance. However, adopting a trial-and-error approach to experimentally evaluate the vast range of process parameters required to capture microstructural variability is cost-prohibitive. Modeling and simulation provide a comparatively inexpensive way to understand and correlate the microstructural evolution to the processing conditions. The modeling and simulation work-packages within the AMMT program aims to use physics-based and machine learning models to develop a digital twin for additive manufacturing that can correlate the process conditions to the final product and establish a process-structure-property-performance (PSPP) correlation. The melting and subsequent solidification that occurs during the additive process is a complex phenomenon that requires multiscale multiphysics analysis. This work package focuses on understanding the role of process variabilities on the unique microstructural characteristics of additively manufactured materials. Microstructural features at the subgrain level, such as compositional micro-heterogeneity and dislocation cells, are of particular interest here since they can influence the creep properties and radiation performance. Idaho National Laboratory’s Multiphysics Object-Oriented Simulation Environment (MOOSE), specifically the MOOSE Application Library for Advanced Manufacturing UTilitiEs (MALAMUTE) software, provides an ideal platform for developing the multiphysics multiscale model to explore the intricacies of the microstructural evolution during the AM processes within a single framework. Furthermore, given that such full-fidelity simulations can be computationally intensive, reduced order models are necessary to explore the PSPP space for additively manufactured materials in an efficient, reliable, and cost-effective way. This work focuses on capturing the microstructural variabilities at the subgrain level that are often missing in the part-scale models. In fiscal year 2025, we significantly advanced upon our work in the last fiscal year, in terms of the predictive capabilities of the physics-based and ML models, by adding the capabilities to capture subgrain-level micro-segregation during solidification using phase-field model and to predict the time-dependent dynamics of the AM process through the MOGPAR model. The alloy solidification model in MOOSE incorporates the thermodynamic properties and free energy relevant to 316 stainless steel. The model demonstrates the Cr and Ni segregation that occurs during solidification, including that the rate of solidification. The microstructural evolution model is connected to the process conditions via the surrogate model developed in this work. This enables predictions of the final microstructure in conjunctions with the manufacturing process. This work supports AMMT's rapid qualification goals by laying the foundation for an efficient and cost-effective model establishing the PSPP correlation for AM. The generated microstructures and predicted micro-segregation can be used by other work packages under AMMT to evaluate the properties and environmental response of the material at the mesoscale. Thus, this work helps to identify the key microstructural features at the subgrain level that are significant in property and performance predictions of additively manufactured components. This work will also provide inputs to the large-scale process variability models to reevaluate and validate assumptions and simplifications made in the part-scale models. Furthermore, through active learning this work can help identify the data need from both modeling and experimental sides for development of a robust digital twin for additive manufacturing and accelerate the AMMT's qualification efforts.

36 - MATERIALS SCIENCE↗
DOE OSTI2026

Preparation of iodine-bearing waste forms for hot isostatic pressing

Oak Ridge National Laboratory (ORNL) has prepared a new set of iodine-bearing sorbents. The sorbent materials used for this activity were supplied by IONEX (NexSorb-99) or C&CS (AC6120-7%). Metal canisters were previously prepared by ORNL in 2022. They are 2 in. long by 1.5 in. in diameter and are made of 316 stainless steel.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Why ionizing radiation enhances surface wettability

Radiation-Induced Surface Activation is an inherent phenomenon where surfaces that are exposed to gamma irradiation are observed to undergo an increase in wettability. This increase in wettability as a result of the ionizing radiation exposure has so far been demonstrated to have a pronounced impact on Leidenfrost temperature and two-phase fluid dynamics. Test results from previous experiments have shown that incorporation of this effect on heat transfer equipment design may increase the thermal-hydraulic margin leading to higher thermal efficiency. However, the mechanism behind the increased wettability is not clearly understood. In the present work, three different materials (Zircaloy-4, 316 stainless steel, and copper) were exposed at two different dose rates with use of two different gamma irradiation facilities. A detailed surface characterization on the post-irradiated samples is carried out to understand the changes in surface chemistry, wettability and surface morphology. It is observed from the experiments that the increase in wettability upon irradiation depended on the total dose and not on the dose rate. Moreover, localized oxidation and porosity induced by radiolysis was seen to be the predominant mechanism behind increased wettability which leads to improved Leidenfrost temperature.

Seshadria, Arunkumar↗
DOE OSTI2020

Elevated-temperature cyclic properties of advanced manufactured materials

Microreactor developers at the 2019 GAIN Microreactors workshop expressed a need for advanced manufacturing to fabricate microreactor components. Powder metallurgy (PM) hot isostatic pressing (HIP) is more mature than other advanced manufacturing techniques for the following reasons: 1. a code case exists for Section III, Division 1, Subsection NB components of light water reactors to be manufactured using PM HIP Alloy 316L, and 2. tensile and creep properties have been shown to be equivalent to wrought material for Type 316 stainless steel and Grade 91. Thus, PM HIP is more readily deployable in the near term. Elevated-temperature cyclic properties of PM-HIP materials, however, have not been established. The scope of testing for Code qualification could be significantly reduced compared to a new material for the following reasons: 1. only a limited amount of time consuming creep testing would be required, and 2. testing of fatigue and creep-fatigue behavior could be reduced if it can be demonstrated that the properties are comparable to wrought material. The objective of this work package is to develop an understanding of the relationship of advanced materials processing on the material characteristics as they relate to elevated-temperature component design and construction. This will be achieved by the following: • Elevated-temperature fatigue and creep-fatigue testing of PM HIP and wrought Alloy 316L. • Fracture and microstructural characterization of the PM HIP and wrought Alloy 316L. • Analysis of the elevated-temperature fatigue and creep-fatigue properties of PM HIP Alloy 316L. • Draft a report evaluating the elevated-temperature fatigue and creep-fatigue properties of PM HIP Alloy 316L. • Pursue procurement of Alloy 316H and Grade 91 manufactured using PM HIP. • Initiate scoping studies of the procured Alloy 316H or Grade 91 manufactured using PM HIP contingent upon successful material procurement.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Calculating Radiation Damage (DPA) from Transmutation Products

This is a poster for an INL poster session. Accurate models for radiation damage are crucial for predicting material performance in radiation environments. The uncertainty of state-of-the-art radiation damage models is large, contributing to excessive safety margins. A major source of this uncertainty is neglecting the effect that transmutation products have on radiation damage. Transmutation products are new nuclides formed by neutron activation during irradiation; they can contribute to radiation damage by additional neutron capture or decay events. Ignoring the contribution of transmutation products leads to a significant underprediction of the radiation damage (e.g., >10% error in 316 stainless steel). This underprediction is accounted for in part by adding larger safety margins to designs. Currently, the state of the art explicitly accounts for only a single transmutation product, namely nickel-59, during the radiation damage calculation. All other transmutation products are assumed to not contribute to the radiation damage, because there is currently no established method to systematically track all or a selection of radiation damage contributions of transmutation products during activation. In the case of nickel-59, the current method is to apply a precalculated correlation that cannot be used for any other nuclide and is largely dependent on all nuclear engineers being experts in this niche topic. This project proposed to methodically find other transmutation products that cause significant radiation damage, and then to develop a general framework for systematically tracking the radiation damage from these nuclides. This was accomplished by combining the radiation damage calculation into the transmutation calculation already performed for irradiated structural materials. The key idea of our framework is to introduce radiation-damage "pseudo-nuclides" to the list of nuclides used in the transmutation analysis. This allows radiation damage to be tracked alongside the creation and destruction of transmutation products. The main deliverable of this project is a general framework for computing radiation damage while the damaged material undergoes transmutation; this capability allows a significantly more accurate estimation of radiation damage, and in turn reduce required safety margins thereby reducing the cost to construct reactors.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Development of Lightweight Structural Materials with Improved Properties for Fission Batteries

Fission batteries require lightweight structural materials that demonstrate structural resilience when subjected to repeated shutdown, transportation, startup cycles, and certain external conditions, including rare events such as seismic vibrations and tsunamis. The objectives of this project are (1) to produce lightweight structural materials whose strength-to-weight ratios and fatigue resistance exceed those of current widely used structural materials such as 316 stainless steels (SS316), and (2) to enhance radiation tolerance of structural materials over a suitable service temperature range. To achieve these, (1) a lattice structure will be produced, (2) advanced modeling and simulation tools will be employed to design lattice structures (e.g., a gyroid structure) that reduce stress concentrations and thus increase fatigue resistance, and (3) one-dimensional (1-D) carbon nanotubes will be added to enhance radiation resistance. To validate our solution, high-temperature tensile and fatigue testing, in combination with microstructure characterization, will be conducted on wrought materials, additively manufactured solid materials, and the designed lightweight lattice structure material. Ion irradiation, microstructure characterization, and nanoindentation will be carried out to investigate the effect of 1-D carbon nanotubes on radiation tolerance. Successful completion of this project will deliver a material to serve as a substitute for current SS316 using the same chemistry but with lighter weight and improved mechanical properties. In addition, a material with carbon nanotubes can be designed for improved radiation tolerance over a suitable service temperature range. This project will establish new techniques in innovative materials/lattice design, advanced macroscale properties prediction, and the application of state-of-the-art processes.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Effect of Si Content in Electrode and SiO2 Additions to the Slag during Electroslag Remelting

Evolution of Si concentration in 316 stainless steel electrodes was observed during a melting campaign consisting of recycling electroslag remelted (ESR) ingots to make new electrodes using vacuum induction melting (VIM). This campaign consisted of iterations of VIM + ESR operations to optimize melting parameters. The effect of Si content on the melt parameters and ingot quality was further evaluated and additions of SiO2 to the slag chemistry were studied using research-scale experiments, x-ray diffraction (XRF), combustion analysis, visual inspections, and computational tools. The Si concentration was found to decrease by approximately 600 ppm following ESR of 150 lb. research-scale electrodes. Eventually, this led to failure of the slag skin and direct ingot/crucible contact. Additions of SiO2 to the slag at levels matching the original calculated Si concentration in the electrode did not eliminate the slag skin failure and the current during steady state increased to maintain a constant melt rate. In this investigation, we propose a mechanism of slag skin failure consisting of local concentration of current density due to absence, or breakage, of the SiO2 layer around the molten metal drop during ESR. This theory was reinforced by additional experiments in which Nb was added to the electrode to change the structure of the oxide layer around the drops.

Jablonski, Paul↗
DOE OSTI2023

Investigation of oxygen evolution reaction with 316 and 304 stainless-steel mesh electrodes in natural seawater electrolysis

Here, two commercially available stainless steel mesh substrates (316 SS and 304 SS) were evaluated as electrodes for oxygen evolution reaction (OER) in natural seawater electrolysis. The results show the 304 SS is less stable against corrosion under neutral (pH of 8.5) and low alkaline (0.1 M NaOH, pH of 12.8) seawater electrolytes because of the direct metal dissolution and chlorine evolution reaction (CER), and the 316 SS is superior to 304 SS in terms of electrocatalytic activity and resistance to corrosion under the same media. The performance of 304 SS is comparable to 316 SS under the high alkaline (1 M NaOH, pH of 13.7) seawater electrolyte, where the CER and metal dissolution are suppressed by OER. The overpotential for 304 and 316 SS is around 430 mV at 10 mA cm -2 , and the Tafel slopes are below 50 mV dec -1 under the high alkaline (1 M NaOH) seawater electrolyte, showing promising performance. The poor resistance to corrosion of 304 SS is attributed to the low Mo content, and it is supposed that the stability of both 304 and 316 SS can be improved further with the addition of Mo content. This work expands on promising substrates for natural seawater electrolysis, with cost and performance advantages.

Stainless-steel mesh↗
DOE OSTI2024

Influence of Spatter on Porosity, Microstructure, and Corrosion of Additively Manufactured Stainless Steel Printed Using Different Island Size

Specimens of 316 L stainless steel were printed using laser powder bed fusion (LPBF), a popular metal additive manufacturing (AM) technique, with varying island sizes. Not many researchers have considered the impact of spatter while optimizing LPBF printing parameters. In this research, the influence of spatter was considered while also investigating the effect of varied island size on the microstructure, surface roughness, microhardness, and corrosion resistance of LPBF-316 L. No correlation was observed between surface roughness or microhardness and minor variations in island size. However, a correlation was drawn between varied island sizes and porosity in LPBF-316 L. The specimens associated with larger island sizes showed significantly enhanced corrosion resistance due to fewer manufacturing defects and reduced porosity, attributed to the minimal influence of the spatter. Based on analysis, the LPBF parameters were revised, which lead to superior corrosion resistance of LPBF-316 L, attributed to high density and reduced porosity.

36 MATERIALS SCIENCE↗
DOE OSTI2023

SA508 low alloy steel to 316L stainless steel dissimilar metal joint made by powder metallurgy hot isostatic pressing

Joining ferritic SA508 low alloy steel (LAS) and austenitic 316 L stainless steel (SS) via powder metallurgy hot isostatic pressing (PM-HIP) was evaluated as an alternative method to welding. This study investigated the mechanical and microstructural evolutions of the bimetallic interface under different joint designs and heat treatments. Here, the direct joining of dissimilar metal alloys by PM-HIP method resulted in two designs: 1) powder SA508 to solid bar 316 L (P508–B316L) and 2) powder 316 L solid bar SA508 (P316L-B508). In both cases, P508–B316L and P316L-demonstrated satisfactory tensile strength, however, high hardness and severe depreciation in toughness were located on the bimetallic interface. The mechanisms responsible for the detrimental mechanical properties were verified. Large oxides were observed in P508–B316L due to the prior powder boundary (PPB) oxides present in SA508 powder. The intense sensitization occurred from the formation of M 23 C 6 carbides, consequently from the slow cooling after PM-HIP in P316L-B508. Post-HIP heat treatments were explored to reduce the distance of carbide formation; however, the heat treatment could not eliminate the carbides. The experimental results were compared to the diffusion couple simulation as a function of carbide formation with distance. The analysis also showed the high hardness at the bimetallic interface was primarily contributed by solid solution strengthening. In conclusion, the direct joining of P316L-B508 and P508–B316L via PM-HIP was deemed to be unfeasible, and a transitional material is necessary to impede the diffusion of carbon.

316L stainless Steel↗
DOE OSTI2024

Development of a MOOSE-based crystal plasticity model with irradiation defect evolution for irradiation creep in 316

Irradiation creep and irradiation swelling are two of the lifetime limiting factors for structural materials in nuclear reactors. These mechanical effects are driven by irradiation defect evolution and the interaction of those defects with dislocations in the microstructure. We present here a coupled cluster dynamics – crystal plasticity approach to model irradiation swelling and creep behavior in 316 SS. The time-dependent evolution of irradiation defects is calculated with a cluster dynamics approach and passed to the crystal plasticity model to compute the dislocation evolution. We show the impact of the irradiation defect evolution on the stress state in the material, which drives inelastic deformation through dislocation motion. The inelastic deformation in the 316 SS is dependent on the dose rate, where the inelastic deformation driven by the early-stage irradiation defect evolution determines the mechanical behavior of the 316 SS.

316 Stainless Steels↗
DOE OSTI2022

Electrochemical corrosion of multiphase stainless steel-based alloy nuclear waste forms

Abstract The electrochemical corrosion behaviors of two multiphase alloys representing waste forms made with 316 L stainless steel and different amounts of surrogate metallic fuel wastes were measured and related to the microstructures. Potentiodynamic (PD) scans were performed in an acid brine solution and the corroded surfaces were characterized with scanning electron microscopy (SEM) to compare the electrochemical responses to the corrosion of specific phases. PD scans for the two multiphase alloys, 316 L stainless steel, and pure palladium were compared to understand the complex corrosion behavior of these multiphase alloys also recently classified as multi principle element alloys (MPEAs) and to determine the effects of alloying elements and noble metals present in constituent phases on the corrosion behavior.

Gattu, Vineeth Kumar (ORCID:0000000307265813)↗
DOE OSTI2026

Influence of Powder Characteristics and Processing Methods on Creep Performance of Powder Metallurgy Hot Isostatic Pressed SS316

The U.S. nuclear energy expansion goals are driving the demand for manufacturing routes that can rapidly produce large, complex, near net shape components. Powder metallurgy hot isostatic pressing (PM HIP) is an advanced manufacturing technique that can be economically scaled-up, while alleviating the supply chain challenges that forging and casting face in terms of cost and lead time constraints. This makes PM-HIP a viable technology to aid and accelerate large-scale part manufacturing for nuclear applications. However, large-scale qualification and deployment of this technology require a thorough understanding of the influence of powder feedstock quality, powder handling history, hot isostatic pressing (HIP) parameters, and subsequent heat treatment on microstructural evolution and elevated temperature mechanical performance. The present work focusses on 316 austenitic stainless steel (SS316) which is most commonly used in high temperature environments for nuclear applications Results from this study show that PM HIPed SS316 meets ASME tensile requirements at room temperature and at elevated temperature. However, creep performance of PM-HIPed SS316 remains inferior to its wrought counterpart, demonstrating that tensile performance alone is not a reliable metric for long duration high temperature integrity. Further, this report delineates powder derived microstructural features that govern creep damage, with key evidences pointing to “microstructural inheritance” from gas atomized powder feedstocks. Commercial SS316 powders of varying chemical compositions and recycling histories were studies, and the results showed large differences in elemental segregation, oxide surface layers and secondary phase distributions. Multi-scale characterization revealed segregation of chromium, molybdenum, manganese and silicon at the boundaries and the precipitation of manganese-, silicon-, and molybdenum-oxides. During HIP consolidation, these surface oxides transform into decorated prior particle boundaries (PPBs) and grain boundary inclusions that persist through conventional post-HIP solution annealing treatment. The retained oxides in post-HIP microstructures were found to influence grain growth, precipitation behavior, and ultimately creep cavitation and fracture. Such post-HIP heat treatments are therefore limited by a complex trade-off between grain growth, and oxide coarsening which aggravate creep damage by acting as nucleation sites for cavities. The objective of this work is to establish an integrated processing–structure–property framework for PM-HIP 316 stainless steel by investigating the influence of powder feedstock characteristics in pre- and post-HIP processing as well as to understand the significance of post-HIP heat treatment on microstructural evolution and creep properties. The results from this report emphasize the significance of powder feedstock integrity in improving creep performance of PM-HIPed SS316, by highlight the effect of rapid solidification, elemental segregation, oxide formation and powder recycling on microstructural defect inheritance following HIP consolidation. Rather than considering HIP processing, solution annealing, and mechanical performance independently, this report treats powder production, HIP consolidation, post-HIP thermal processing, and creep deformation as interconnected stages within a continuous metallurgical process. The resulting framework will provide a scientific basis for developing feedstock engineering strategies capable of improving long-term reliability of PM-HIP stainless steels and accelerating their qualification for advanced nuclear applications.

Ajjarapu, Pavan [Oak Ridge National Laboratory (OR↗
DOE OSTI2022

Synthesis of a 316L stainless steel-copper composite by laser melting

This paper demonstrates a laser melting method to produce a metal matrix composite with a higher thermal conductivity compared to 316 L stainless steel using a Jettable Cu ink. A novel canister was used to control the oxygen level during laser processing to emulate a hybrid inkjet-powder bed fusion technique for doping the stainless steel powder bed with Cu precursor ink. Here, the thermal conductivity of the composite was found to be 187% higher than that of 316 L stainless steel, while the microhardness decreased by 39%. Microstructural results show opportunities to further enhance the thermal conductivity and mechanical properties of the composite by eliminating interfacial cracking.

36 MATERIALS SCIENCE↗