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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 1,477 records · Page 82
All sourcesNASA NTRSDOE OSTI
DOE OSTI2017

Prediction of Thermal Transport Properties of Materials with Microstructural Complexity

This project aims at overcoming the major obstacle standing in the way of progress in dynamic multiscale simulation, which is the lack of a concurrent atomistic-continuum method that allows phonons, heat and defects to pass through the atomistic-continuum interface. The research has led to the development of a concurrent atomistic-continuum (CAC) methodology for multiscale simulations of materials microstructural, mechanical and thermal transport behavior. Its efficacy has been tested and demonstrated through simulations of dislocation dynamics and phonon transport coupled with microstructural evolution in a variety of materials and through providing visual evidences of the nature of phonon transport, such as showing the propagation of heat pulses in single and polycrystalline solids is partially ballistic and partially diffusive. In addition to providing understanding on phonon scattering with phase interface and with grain boundaries, the research has contributed a multiscale simulation tool for understanding of the behavior of complex materials and has demonstrated the capability of the tool in simulating the dynamic, in situ experimental studies of nonequilibrium transient transport processes in material samples that are at length scales typically inaccessible by atomistically resolved methods.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Microstructure-sensitive Crystal Viscoplasticity for Ni-base Superalloys Targeting Long-term Creep-Fatigue Interaction Modeling

This report introduces a new temperature-dependent, microstructure-sensitive crystal viscoplasticity model for single-crystal Ni-base superalloys. The model predicts the material response of the single-crystal components in the hot gas path sections of industrial gas turbines. The influence of changes in the microstructure that occur with aging in service, critical to predicting long-term creep-fatigue interactions, is embedded into the model through the γ' precipitate morphology evolution. The model is calibrated to predict the experimental response of CMSX-8, a lower cost variant of the second generation single-crystal superalloy CMSX-4. In addition, the experimentally-measured creep-fatigue and thermomechanical fatigue behavior of CMSX-8 is reported.

03 NATURAL GAS↗
DOE OSTI2018

Controlling microstructure in deposits fabricated using powder blown direct energy deposition technique

The overall goal of this collaboration is to develop technologies to control grain morphology and microstructures of Inconel 718 components additively manufactured through the Direct Energy Deposition (DED) process (Identical to the LENS (laser engineered net shaping) processes) and to achieve equiaxed or near equiaxed grain structures. The phase1 technical collaboration was used to fabricate Inconel 718 builds with different process parameters, pre heat and scan strategies. The results were then rationalized using computational heat transfer and solidification models. Microstructural characterization showed that the aspect ratio of the grains can be reduced to less than 1.5, and that control of the grain sizes to within 50-100 μm could be potentially obtained by using an external source to preheat the substrate to 400 ̊C. Heat transfer models coupled with solidification models were used to rationalize the results which show that preheating lowered the temperature gradient thereby resulting in moving towards the equiaxed region of the columnar to equiaxed transition (CET) curve. The results demonstrate that higher preheat temperatures could be potentially used to obtain a truly equiaxed structure.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Laser Intensity Profile Effects on the Solidification Microstructure of Ti-6Al-4V and Ti-5553

Traditional machining of Ti-6Al-4V and Ti-5Al-5Mo-5V-3Cr (Ti-5553) is challenging due to high chemical reactivity, adiabatic shear band formation, and material cost. Titanium is attractive because of its high tensile strength, low density, corrosion resistance, and ability to withstand extreme temperatures. Selective Laser Melting (SLM) is capable of manufacturing geometrically complicated parts at a lower expense. Exceptional tolerances can be obtained with properly tuned processing parameters. Alterations on scan parameters permit microstructure and melt pool control. Single track laser melting experiments were performed on Ti-6Al-4V and Ti- 5553 using elliptical intensity profiles. Results show that maintaining constant energy density but increasing power results in a melt pool failing to penetrate the substrate for Ti-5553. Increasing laser energy density increases melt pool width and can increase powder bed denudation. Comparing Ti64 and Ti-5553 microstructures contributes to a better understanding of rapid solidification in titanium.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Mechanical properties and microstructure characterization of unirradiated Eurofer-97 steel variants for the EUROfusion project

To understand the microstructure and mechanical property degradation of various Eurofer-97 steel variants being neutron irradiated at HFIR up to 2.5 and 20 dpa for the EUROfusion programme, it is necessary to develop a general understanding of these steels in non-irradiated form. In this context, room temperature mechanical property evaluation tests and multi-length scale microstructure characterization of the different Eurofer-97 steel variants: H, I, J, K, L, M, N, O, P and reference E series steels, was performed at ORNL. Mechanical tests consisted of Vickers hardness indentation measurements, uniaxial tensile tests and fracture toughness tests.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2017

Microstructure-Level Modeling of Stage 3 Fission Gas Release in UO 2 Fuel

A new phase-field model of fission gas bubble evolution was developed and applied to gain an improved understanding of the microstructure-level processes leading to fission gas release from nuclear fuel and to inform improvements to the fission gas release model used in BISON. The phase-field model simulates the evolution of multiple fuel grains and intergranular bubbles simultaneously, tracks the local concentration of vacancies and gas atoms, and includes the effect of hydrostatic gas pressure on the surrounding fuel matrix. This represents the most realistic microstructure-level model of fission gas bubbles developed to date. The model was used to simulate the growth of grain face and grain edge bubbles in a hexagonally periodic 3D grain structure, which contains multiple grain boundaries and triple junctions. The coverage of grain boundaries and triple junctions by fission gas bubbles was calculated as a function of time. Preliminary results suggest that grain edge bubbles do not release a significant amount of gas prior to gas release by grain face bubbles, which supports the assumptions of the fission gas release model currently used in BISON. However, the simulations should be improved by including a physically realistic number of grain edge bubbles in the initial conditions before definitive conclusions can be drawn.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2019

Complete Status Report Documenting the Processing, Microstructure and High-Temperature Mechanical Properties of the Nanostructured Ferritic Alloy OFRAC

This report provides a summary of the new nanostructured ferritic alloy, OFRAC (Oak Ridge Fast Reactor Advanced Fuel Cladding), that was developed for the advanced sodium fast reactor fuel cladding and core internals. The composition of OFRAC, which is Fe-12Cr-1Mo-03.Ti-0.3Nb + 0.3Y2O3 (wt. %), was chosen to achieve high temperature strength as well as high temperature creep performance and swelling resistance requirements that past structural materials such as austenitic stainless steels and ferritic/martensitic steels, i.e. HT-9, are not suitable as SFR cladding materials. The mechanical alloying procedures were described for producing OFRAC and the detailed characterization studies revealed uniformly distributed, high concentration of Y-Ti-O enriched oxide particles, or nanoclusters. The Nb addition that was intended to sequester interstitial C and N that are commonly introduced as contamination during ball milling of powder was found to be very effective in forming coarse size Nb carbonitrides along with excess Ti that removes these interstitial elements from the bcc-Fe matrix of OFRAC. The tensile tests on the OFRAC in the extruded condition showed excellent balance in strength and ductility from room temperature to 800°C. Both the microstructure and tensile properties were not significantly degraded after annealing the extruded OFRAC samples for 8 h at 1050°C and 1150°C. The latter temperature is ~76% of the melting point of OFRAC. These results demonstrated the stability of the microstructure and tensile properties to extremely high temperatures. The thermal creep resistance at elevated temperatures and stresses was investigated using strain rate jump testing. The results showed that OFRAC possessed high stress exponents at high stresses and temperatures of 550°C, 600°C, 700ºC and 800°C. This thermal dependence of minimum creep rate indicates that OFRAC will show quite low creep rates at higher temperatures and stresses compared to HT-9 and stainless steels. These significant improvements indicate that the NFA OFRAC alloy is a compelling and viable choice for sodium fast reactor fuel cladding.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2019

Modeling and Simulation of Microstructure Evolution and Deformation in an Irradiated Environment

The ability to predict the behavior of structural components in a nuclear power plant is critical to the nuclear industry. Structural metals in the primary loop of nuclear power plants must endure challenges such as irradiation and mechanical and thermal loading, and these structural metal components must continue to function in potential transient and accident conditions throughout the operational lifetime of the power plant. This extreme operational environment changes the metal microstructure by creating additional defects. The physical interactions of dislocations with these defects govern how the metal will respond to future conditions. Therefore predicting the mechanical response of these metals requires a set of physically based and reliable models of dislocation and defect interactions. These microstructure elements include glide mobile and immobile dislocations, geometrically necessary dislocations, twinning dislocations, irradiation defects, and thermal aging defects. We present here a continuum dislocation dynamics crystal plasticity framework to capture the interaction mechanisms of these dislocations and defects, verified with a combination of benchmark problems and comparisons with experimental data for two different types of structural metals: alpha iron and nickel-based alloys. In our simulations of $\alpha$ iron we highlight the advantages of applying a Monte Carlo stochastic model of cross slip dislocation motion and show the importance of capturing the 3D nature of glide dislocation and self-interstitial atom loop radiation defect interactions. We demonstrate coupling of glide dislocations with geometrically necessary dislocations to capture the influence of lattice bending, including the sensitivity of the geometrically necessary dislocations to changes in the grain boundary angle. We further examine the interaction of glide dislocations with the twin dislocations and thermally aged defects which have been observed in a nickel-based alloy with additional models. Finally we assess the reliability of this crystal plasticity framework by comparing two dislocation glide velocity models across the range of normal operation temperatures. In successfully applying our crystal plasticity framework to multiple metals, we provide further evidence of the reliability of our approach. The results of this mechanism-based continuum dislocation dynamics crystal plasticity framework can be used to inform engineering scale models throughout the nuclear industry.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Microstructural Characterization of High Dose Irradiated HT9

The present report provides a short summary of the recent efforts to irradiate various HT9 heats and compositions to a high damage level (>500 peak dpa) and characterize the changes to the microstructure. The majority of the data reported here will focus on characterizing the “INL” HT9 heat. This particular heat was chosen due to its high volume fraction of tempered martensite (>90%) in the microstructure. The results show that very little swelling is present in INL HT9 up to doses up to 600 peak dpa. Voids are only observed in the near surface region. Some carbides are also observed to accompany the irradiation. Comparison of void swelling with published neutron irradiation shows good agreement. Additional investigations into the response of delta ferrite grains show a very different distribution of voids and significantly higher void swelling compared to the tempered martensite grains.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2019

Microstructural Modification and Healing of Additively Manufactured Parts by Electropulsing

For many applications, the promises of additive manufacturing (AM) of rapid development cycles and fabrication of ready-to-use, geometrically-complex parts cannot be realized because of cumbersome thermal postprocessing. This postprocessing is necessary when the nonequilibrium microstructures produced by AM lead to poor material properties. This study investigated if electropulsing, the process of sending high-current-density electrical pulses through a metallic part, could be used to modify the material properties of AM parts. This process has been used to modify conventional wrought materials but has never been applied to AM materials. Two representative AM materials were examined: 316L stainless steel and A1Si10Mg. Two hours of annealing are needed to remove chemical microsegregation in AM 316L; using electropulsing, this was accomplished in 200 seconds. The ductility of AlSil0Mg parts was increased above that of the as-built material using electropulsing. This study demonstrated that electropulsing can be used to modify the microstructures of AM metals.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Thermal Conductivity Measurement of Microstructure in Irradiated Materials

Argonne National Laboratory is establishing additional capabilities for advanced techniques for accelerated experiment-based fuel material screening. A key supporting element is expanded capabilities for the characterization of irradiated samples, including establishment of the capability to measure irradiated fuel thermal conductivity at the micro-scale level. Argonne is collaborating with the University of Illinois at Urbana-Champaign (UIUC) to adopt the suspended bridge method to measure thermal conductivity of radiation-induced microstructures in nuclear materials directly. The initial phase of work to support thermal conductivity measurements of microstructure in irradiated materials at Argonne has been executed, and is summarized here. This report is intended to serve as a status update for this activity, summarizing work completed in FY20.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Microstructure and Mechanical Performance of the Friction Stir Welds Made on Neutron-Irradiated Steel with Helium

This report describes new experimental results on the microstructure and mechanical performance of the friction stir welds made on neutron-irradiated steel with helium. The report focuses on helium-related issues, specifically, helium-induced degradation in the welded joint, aiming to repair irradiated components of nuclear power plants (NPPs). The friction stir welds analyzed here were produced at Oak Ridge National Laboratory previously, and limited characterization work was performed, mostly addressing the presence or absence of macroscopic cracks. The present work attempts to perform a more comprehensive study to assess microstructure conditions, grain size, plastic strain gradients, the morphology of the helium-induced damage, and deformation behavior.

42 ENGINEERING↗
DOE OSTI2019

Mechanofusion for Improved Control of Cermet TPBAR Pellet Microstructure

Mechanofusion is an alternative fabrication technique that has the potential to advance cermet TPBAR pellets by producing LiAlO 2 -Zr core-shell powders that will provide tighter control of targeted microstructural characteristics such as the presence and thickness of Zr surrounding every LiAlO 2 particle in the cermet. Significantly enhanced microstructural control will translate to improved control of material properties and characteristics that affect the in-reactor performance of cermet TPBAR pellets. It was the intention of this work to demonstrate the efficacy of mechanofusion for producing precursor powders for TPBAR pellets, however materials procurement issues prevented this objective from being fully realized. In spite of these issues, in the short amount of time during which appropriate materials were available, it was demonstrated that mechanofusion does indeed have promise for producing the desired structures although the process yet requires optimization.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Microstructural Investigation of Precipitation Treated A709 Test Samples

This report presents the microstructural characterization using scanning transmission electron microscopy (STEM) of two creep-tested ESR1150-PT specimens, one short-term and one long-term. The results show that during creep testing, the microstructure of the A709 ESR1150-PT material continues to evolve as expected due to the synergistic effect of strain, temperature and time. Key features include dislocation forest and cell structures, precipitates on grain boundaries, precipitates randomly within grains, and precipitates associated with dislocations. In addition, the STEM study of one ESR1100-SA specimen that has been tested to rupture at a relatively low temperature (550°C) for a relatively long term (16226 h) is also presented. The results show that there is a high density of very fine nano precipitates form on dislocations.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Prediction of the influence of strain magnitude and strain path on the resulting microstructure and post-forming mechanical behavior of RA containing high formability steels

In third generation advanced high strength steels (AHSS) there is considerable potential to alter the transformation characteristics through variation of process parameters and through changes in chemical composition. This proposal aims to utilize this known phenomenon to develop microstructure-based transformation models to predict austenite stability as a function of chemical composition, strain level, deformation mode. The ultimate intent is to predict microstructure and performance during room temperature forming to produce automotive structural components with superior strength and failure resistance.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Engineering & Microstructure Scale PIE Report on EBR-II X441A Metallic Fuel Pins for the MORPH Experiment

The objectives of this project are to increase fundamental understanding of irradiation induced metallic U-Pu-Zr fuel behavior and to obtain data needed for the development of irradiation models for metallic fuels in MARMOT. The requested metallic fuel pins are from the X441A experiment irradiated in Experimental Breeder Reactor (EBR)-II and will be provided by the PIs for the duration of the experiment. The purpose of the pins irradiated in the X441A assembly was to vary Zr composition and fuel slug diameter in order to provide data for the metallic fuel performance code “LIFEMETAL” [ANL-IFR-125]. The fuels of interest to this project are metallic fuels with several Zr compositions (in wt.%): U-19Pu-6Zr, U-19Pu-10Zr, and U-19Pu-14Zr, which were irradiated to a peak burnup of approximately 11 at.%. The cladding was the same for all three fuel pins (austenitic stainless steel D9), which allows investigation of fuel-cladding interaction (FCI) phenomena. Varying Zr content in fuel pins enables investigation of the effect of Zr on fuel restructuring and fuel-cladding compatibility. Engineering and microstructure scale PIE activities will be focused on investigation of fundamental aspect of fuel performance such as species diffusion and migration, fission product behavior, and constituent redistribution. Obtained microstructural information will be used as the basis for the development of MARMOT models of U-Pu-Zr fuel performance at the mesoscale. Experimental data obtained through this proposal will be used to provide this fundamental understanding which will serve as the foundation of the development of radiation models for U-Pu-Zr in MARMOT. It will also provide a starting point for the design of new experiments to provide data for the validation of these MARMOT models.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Microstructure and in-service degradation of baffle former bolts – in-core components of light water reactors

This report presents a microstructure evaluation of the baffle former bolt, a commercial pressurized water reactor component. Using SEM, EDS, and EBSD analysis the material was identified as AISI 316 steel with an annealed austenite microstructure. Findings include abnormal grain growth in a fraction of the grains and the absence of retained ferrite. Notable observations include an overlapping of pre- and post-irradiation deformation, including defect-free channel formation as an active deformation mechanism in the near-surface layer of BFB. Specimen surfaces, exposed to high-temperature, high-pressure water, exhibited signs of in-service corrosion degradation. EBSD and EDS analyses highlighted intergranular corrosion, possible grain boundary oxidation with depths less than 3 µm, and, unexpectedly, short cracks filled with Cr-rich oxides measuring around 5-6 µm. The presence of defect-free channels from EBSD data suggests episodes of high mechanical stresses during service. The specimens provide a potentially unique insight into the in-service degradation of NPP components, strain localization, and crack initiation processes. An intact corrosion layer reveals a complex component's in-service history. Further research is underway for a detailed analysis.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Investigation on laser absorption and x-ray radiation in microstructured titanium targets heated by short-pulse relativistic laser pulses

The enhancement effect of a microstructured surface on laser absorption and characteristic Kα emission has been investigated by measuring K-shell emission from titanium (Ti) targets irradiated with high-intensity (~10 20 W cm -2 ), subpicosecond (500 fs) laser pulses. The experimental results indicate a modest enhancement (1.6×) of Kα emission from microstructured targets compared to flat foils, but with a similar intensity and profile of Heα and Li-like satellites. Particle-in-cell (PIC) simulations are implemented to further understand the underlying physical processes in the laser interaction with both targets, interpreting the mechanisms responsible for the Kα enhancement. The reasons for the lower-than-expected enhancement of Kα emission are discussed. The rapid heating of the bulk plasma might result in the premature shutdown of Kα emission before the thermalization of hot electrons or even the end of laser pulses, suggesting that the use of Kα emission as a diagnostic of the hot-electron yield or relaxation could lead to a misinterpretation.

36 MATERIALS SCIENCE↗