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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 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Anisotropic spall failure of additively manufactured 316L stainless steel

The dynamic high strain rate tensile (spall) failure of additively manufactured (AM) materials is an area of great interest but much less understood than material failure under other loading regimes. The research presented here examines the effects of microstructure anisotropy in 316L stainless steel fabricated by laser powder bed fusion (LPBF) on its spall failure and properties. In this work, plate-on-plate impact experiments were performed using an 80-mm gas gun to investigate the spall behavior of AM fabricated sample discs with impact along the perpendicular and parallel orientations relative to build directions. Experiments were also performed on wrought 316L stainless steel as baseline material with uniform equiaxed grain microstructure for comparison with the AM material of same composition. The spall experiments involved free-surface velocity profiles measured using Photon Doppler Velocimetry (PDV) to capture the spall pull-back signals, combined with post-mortem analysis of the microstructure of soft-recovered impacted samples. In the case of AM samples, spall failure initiated preferentially at melt pool boundaries in both impact directions. The spall plane location and spall strength, however, were both heavily influenced by the orientation of the impact direction relative to the build direction in the AM samples. The spall behavior is also observed to be more complex in the samples impacted perpendicular to the build (through-thickness) direction, due in large part to the orientation of the microstructural features such as melt pool boundaries, laser scan tracks, and general grain morphology.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Martensitic transformation induced strength-ductility synergy in additively manufactured maraging 250 steel by thermal history engineering

Maraging steels are known for their exceptional strength but suffer from limited work hardening and ductility. Here, in this study, we report an intermittent printing strategy to tailor the microstructure and mechanical properties of maraging 250 steel via tuning the thermal history during wire-arc directed energy deposition. By introducing a dwell time between adjacent layers, the maraging 250 steel is cooled below the martensite start temperature, triggering thermally-driven martensitic transformation during the printing process. Thermal cycling during subsequent layer deposition results in the formation of reverted austenite which shows a refined microstructure and induces elemental segregation between martensite and reverted austenite. The Ni enrichment in the austenite promotes stabilization of the reverted austenite upon cooling to room temperature. The reverted austenite is metastable during deformation, leading to strain-induced martensitic transformation under loading. Specifically, a 3 min interlayer dwell time produces a maraging 250 steel with approximately 8% reverted austenite, resulting in improved work hardening via martensitic transformation induced plasticity during deformation. Meanwhile, the higher cooling rate and refined prior austenite grains lead to substantially refined martensitic grains (by approximately fivefold) together with an increased dislocation density. With 3 min interlayer dwell time, the yield strength of the printed maraging 250 steel increases from 836 MPa to 990 MPa, and the uniform elongation is doubled from 3.2% to 6.5%. This intermittent deposition strategy demonstrates the potential to tune the microstructure of maraging steels for achieving strength-ductility synergy by engineering the thermal history during additive manufacturing.

Additive manufacturing↗
DOE OSTI2023

In Situ X-ray Diffraction Investigation of Hydrogen Effects on Deformation-Induced Phase Transformation in Forged and Additively Manufactured 304L Stainless Steels

Here, this study utilized high energy synchrotron x-ray diffraction to probe microstructural evolution during uniaxial deformation of conventionally manufactured and additively manufactured (AM) 304L stainless steel with and without internal hydrogen. The objective of this effort is to highlight the effect of hydrogen on deformation-induced martensite phase transformations in austenitic stainless steels. Solute hydrogen depresses the required applied strain to initiate austenite transformation to ε-martensite and α'-martensite in both forged and AM stainless steel. Similarly, the total fraction of transformation product is larger when the microstructure is saturated with hydrogen. Deformation induced phase transformations also lead to a variation in strain partitioning behavior, which is linked to the chemical composition and stacking fault energy of the starting and hydrogen-charged materials.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Enhancing Surface Finish of Additively Manufactured 316L Stainless Steel with Pulse/Pulse Reverse Electropolishing

To improve the reliable integration of additively manufactured (AM) metal components, there is an urgent need for surface finishing methods capable of processing rough, “as-printed” surfaces. Here, we present a new and scalable electropolishing (EP) technique for use on AM 316L stainless steel (SS) that is capable of achieving a surface roughness equivalent to a machined finish, with arithmetic mean heights (S a ) as low as 1.0 µm. This technique utilizes the sequential application of a new, NaCl/H 2 O pulse/pulse reverse (P/PR) EP step along with a conventional DC (direct current) EP step, where P/PR expands the capability of EP by removing roughness features > 1 µm, which has been previously unattainable with DC EP alone without substantial material removal. This is achieved by independently varying pulse parameters, such as pulse width and height, allowing more control over electrodynamic processes at the part-electrolyte interface. Additionally, P/PR EP resulted in higher smoothing efficiency, where a higher degree of smoothing was achieved with less material removal when compared with conventional DC EP alone. This minimizes unwanted change in geometry from excessive metal dissolution.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Micropillar Compression of Additively Manufactured 316L Stainless Steels after 2 MeV Proton Irradiation: A Comparison Study between Planar and Cross-Sectional Micropillars

A micropillar compression study with two different techniques was performed on proton-irradiated additively manufactured (AM) 316L stainless steels. The sample was irradiated at 360 °C using 2 MeV protons to 1.8 average displacement per atom (dpa) in the near-surface region. A comparison study with mechanical test and microstructure characterization was made between planar and cross-sectional pillars prepared from the irradiated surface. While a 2 MeV proton irradiation creates a relatively flat damage zone up to 12 µm, the dpa gradient by a factor of 2 leads to significant dpa uncertainty along the pillar height direction for the conventional planar technique. Cross-sectional pillars can significantly reduce such dpa uncertainty. From one single sample, three cross-sectional pillars were able to show dpa-dependent hardening. Furthermore, post-compression transmission electron microscopy allows the determination of the deformation mechanism of individual micropillars. Cross-sectional micropillar compression can be used to study radiation-induced mechanical property changes with better resolution and less data fluctuation.

transmission electron microscopy↗
DOE OSTI2023

Preliminary Characterization and Evaluation on FFF Manufactured 316H and ODS Steels

The Advanced Materials and Manufacturing Technology (AMMT) program develops cross-cutting technologies in support of a broad range of nuclear reactor technologies and maintains U.S. leadership in materials and manufacturing technologies for nuclear energy applications. The overarching vision of AMMT is to accelerate the development, qualification, demonstration, and deployment of advanced materials and manufacturing technologies to enable reliable and economical nuclear energy. Solid-state advanced manufacturing techniques can overcome some of the challenges in liquid-based additive manufacturing (AM) processes and should therefore be considered in material design and manufacturing as well. The work presented in this report forms part of a study on solid-state AM techniques of 316 stainless steels (SS) and oxide dispersion strengthened (ODS) steel components and supports the vision and goals of the AMMT program relevant to accelerate the development and deployment of advanced manufacturing processes. Achieving this can provide a safety improvement through larger safety margins, economic benefit for higher efficiency during operation, and a cost reduction through more effective manufacturing processes and less waste. This study provides preliminary information on development of the fused-filament fabrication (FFF) process using different powder types to demonstrate the sensitivity, and therefore the characterization of these sample components. The full solid-state manufacturing feasibility study will be completed and reported in a final feasibility evaluation during 2025. The study investigation used two 14YWT ODS powder batches, which provided information and the effect of different powder morphologies on manufacturability. The two 316SS powders demonstrated the effect of powder size on the manufacturability using FFF. Two product forms, namely a honeycomb structure and flat samples, were manufactured to demonstrate the flexibility of product form.

36 MATERIALS SCIENCE↗
DOE OSTI2020

High-throughput experimentation for microstructural design in additively manufactured 316L stainless steel

In the present study, a combination of high-throughput (HT) and low-throughput (LT) techniques was used to rapidly determine the processing window and generate processing maps for Selective Laser Melting (SLM) of 316L stainless steel. The HT method includes the fabrication of hundreds of hex nut-shaped specimens, each processed with a unique combination of laser power, scanning speed, and hatch spacing. An easily removable scaffolding permitted rapid sample extraction from the base plate, thus saving machining cost and time. Hardness and immersion density measurements were used for HT characterization to identify a processing window for maximum strength and density. Within the defined processing window, a low-throughput (LT) microstructural interrogation of specimens were performed. The microstructural analysis included quantification at various length scales (i.e., grains size and morphology, texture, primary dendrite arm spacing, and melt pool geometry analysis). Microstructure-based processing maps as a function of volumetric energy density were generated. The combination of HT and LT methods produced a predictive relationship between hardness and primary dendrite arm spacing using a Hall-Petch relationship. A model is proposed to explain the dependence of microstructure on the melt pool geometry. Here, the HT method can be applied for the microstructural design of SLM-fabricated components in other alloys.

316L stainless steel↗
DOE OSTI2020

Mechanical Properties and Deformation Behavior of Additively Manufactured 316L Stainless Steel (FY2020)

The Transformational Challenge Reactor (TCR) program plans to build most of the TCR core components through additive manufacturing (AM) processes. These processes include laser powder bed fusion (LPBF) for the metallic (316L) components and the newly developed combined process of binderjet printing and chemical vapor infiltration (CVI) for the SiC fuel matrix. Mechanical testing and characterization tasks have been carried out since the beginning of the TCR program to (1) build a property database for the AM materials that will be used in TCR core and (2) to assess the materials’ performance in TCR-relevant conditions. This document reports the outcome of the testing and characterization efforts for the fiscal year with a focus on the mechanical performance data of AM 316L stainless steel (SS). Baseline tensile testing over a wide temperature range of room temperature–600 °C was completed for the AM 316L alloy in as-built, stress-relieved, and solution-annealed conditions. The as-built 316L showed the highest strength, and the alloy after the post-build treatments showed reduced strengths in the low-strain range. However, the strength differences among the AM materials became insignificant in the later part of deformation. Furthermore, regardless of post-build processing, the AM 316L SS showed higher strength and comparable ductility when compared with wrought 316L SS. Thermal creep testing and microstructural evolution during creep deformation were also performed under selected conditions. It was found that the AM 316L steel showed the best creep resistance in the stress-relieved condition. In-situ tensile tests were performed using scanning electron microscopy and 1-ID beamline at the Advanced Photon Source to elucidate the deformation and fracture behavior of AM 316L and the evolution of crystalline stress, dislocations, and pore distribution. Using these in-situ testing data, an in-depth analysis of the roles of microstructural features in deformation and fracture processes is presented herein. The final section of the document introduces ongoing and future activities for materials testing and characterization, including irradiation effect studies and ball punch testing on AM 316L and AM IN718 alloys.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2024

Performance Testing of Additively Manufactured 316L Stainless Steel in Light Water Reactor Environment

This report summarizes research activities conducted at Argonne National Laboratory in support of the development, qualification and certification of additively manufactured (AM) metallic components for the long-term sustainability of light water reactors. In this program, AM 316L stainless steel (SS) has been evaluated in light water reactor (LWR) environments for their fatigue, environmentally assisted fatigue, and stress corrosion cracking performances on specimens in as-printed condition, aiming for facilitating the regulatory acceptance and ultimately adoption of AM components in aging LWRs.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

Complementary Measurements of Residual Stresses Before and After Base Plate Removal in an Intricate Additively-Manufactured Stainless-Steel Valve Housing

Residual stress measurements using neutron diffraction and the contour method were performed on a valve housing made from 316 L stainless steel powder with intricate three-dimensional internal features using laser powder-bed fusion additive manufacturing. The measurements captured the evolution of the residual stress fields from a state where the valve housing was attached to the base plate to a state where the housing was cut free from the base plate. Making use of this cut, thus making it a non-destructive measurement in this application, the contour method mapped the residual stress component normal to the cut plane (this stress field is completely relieved by cutting) over the whole cut plane, as well as the change in all stresses in the entire housing due to the cut. The non-destructive nature of the neutron diffraction measurements enabled measurements of residual stress at various points in the build prior to cutting and again after cutting. Good agreement was observed between the two measurement techniques, which showed large, tensile build-direction residual stresses in the outer regions of the housing. The contour results showed large changes in multiple stress components upon removal of the build from the base plate in two distinct regions: near the plane where the build was cut free from the base plate and near the internal features that act as stress concentrators. These observations should be useful in understanding the driving mechanisms for builds cracking near the base plate and to identify regions of concern for structural integrity. Neutron diffraction measurements were also used to show the shear stresses near the base plate were significantly lower than normal stresses, an important assumption for the contour method because of the asymmetric cut.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Microstructural banding of directed energy deposition-additively manufactured 316L stainless steel

The microstructures of 316 L stainless steel created by rapid solidification are investigated here by comparing the similar microstructures of individual hatches of directed energy deposition additive manufacturing (DED-AM) and those of single, laser surface-melted tracks formed on a solid plate. High recoil pressure, which is exponentially dependent on the laser beam power density, induces convection of the melt pool, which causes formation of microstructural bands in the as-solidified microstructure. The microstructural bands are associated with changes in the chromium concentration and are a significant component of the inhomogeneous microstructure of DED-AM.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Benchmarking a 9Cr-2WVTa Reduced Activation Ferritic Martensitic Steel Fabricated via Additive Manufacturing

Reduced activation ferritic (RAF) martensitic steels are promising candidates for the first wall of fusion reactors. However, current manufacturing capabilities call for these components to be made by welding wrought plates. This limits design freedom and necessitates the use of post-weld heat treatments (PWHT) in accordance with the boiler and pressure vessel code. Additive manufacturing (AM) can offer a unique solution to solve this challenge by leveraging the layer-wise deposition strategy to come up with temper bead deposition techniques to eliminate post-processing heat treatments (PPHT). However, it is necessary to benchmark the properties of RAF steels fabricated by AM with their wrought counterparts to identify the process-structure-property correlation, which is the goal of this study. The study demonstrates that while tensile properties at room temperature and high temperatures are satisfactory, the as fabricated and samples after PPHT have significant heterogeneity in tensile elongation. This has been attributed to the presence of discontinuities in the build. The as-fabricated samples have an average tensile strength of 1190 + 12 MPa and an average elongation of 15 + 5% at room temperature and 658 ± 20 MPa ultimate tensile strength (UTS) and 14 ± 7% at 600 °C. After the post-weld heat treatment, mechanical properties decrease to around 600–650 MPa and an elongation between 20–25% at room temperature to 300 MPa UTS and 25–28% elongation at 600 °C. The characterization of microstructures at various length scales demonstrates that the as-fabricated structure has a significant fraction of delta ferrite in a lath martensitic matrix. No precipitates could be identified in the as-fabricated structure. PPHT led to a decrease in the area fraction of delta ferrite and precipitation of M 23 C 6 and MX. Detailed characterization clearly demonstrates that the lack of precipitates in the as-fabricated structure could be due to the slow tempering response of the alloy. Finally, the needs to develop new alloys to achieve the objectives stated above are articulated.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Spatially resolved phase transformation mapping in 410 stainless steel during additive manufacturing visualized via real-time infrared data

Here, in this study, we demonstrate that spatially resolved cooling curves derived from real-time infrared (IR) thermography during additive manufacturing (AM) can capture spatial variations in phase transformation temperatures through cooling curve analysis (CCA). Using this approach, we show that during laser hot-wire deposition of 410 stainless steel (410SS), the martensite start temperature (M s ) evolves dynamically throughout the build. The M s temperature is spatially nonuniform, ranging from 185 °C to 348 °C, with the lowest values toward the build center and higher values toward the upper region of the deposit. In the lower portion of the build, no M s inflection is detected via CCA, consistent with transformation occurring earlier during thermal cycling followed by tempering during subsequent thermal cycles. These trends in M s are corroborated by characterizing the microstructure by electron backscatter diffraction (EBSD). Traditionally, M s is assumed to be constant, and a single interpass temperature is applied during both deposition and residual stress modeling. Our results demonstrate that IR-derived cooling curves provide a route to spatially and temporally resolved transformation temperature tracking for dynamic interpass control and improved residual-stress modeling.

Additive manufacturing↗
DOE OSTI2021

Transient Deformation in Additively Manufactured 316L Stainless Steel Lattices Characterized with in-situ X-ray Phase Contrast Imaging: The Complete Dataset for Three Geometrical Lattices

Metallic lattice structures are being considered for shock mitigation applications due to their superior mechanical properties, energy absorption capability and lightweight characteristics inherent of the additive manufacturing process. In this study, shock compression experiments coupled to x-ray phase contrast imaging (PCI) were conducted on 316L stainless steel lattices. Meso-scale simulations incorporating the as-built lattice structure characterized by computed tomography were used to simulate PCI radiographs in CTH for direct comparison to experimental data. The methodology presented here offers robust validation for constitutive properties to further our understanding of lattice compaction at application-relevant strain rates.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Atomistic Modeling of Irradiation-Induced Defects and Clusters in Additively-Manufactured Austenitic Stainless Steel

Understanding the progression of irradiation-induced defects in real materials and alloys requires insight into the interaction between point defects, defect clusters, and the existing microstructure. This is particularly true when it comes to additively manufactured (AM) materials with complicated microstructures and residual stresses. In this work, we employ molecular dynamics (MD) to simulate the creation of point defects via primary radiation damage modeling and point defect interactions with extended defects such as voids and dislocations using simplified but representative alloy compositions. We analyze the effect of alloying elements on the formation energies of the defect clusters and measure interactions such as sink strengths and binding energies. This study provides insight into the unique behaviors of irradiation damage in AM materials and information necessary to bridge the gap in length and time scales to connect the atomistic behavior of defects to longer length scale simulations such as cluster dynamics.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Investigation of Deformation Behavior of Additively Manufactured AISI 316L Stainless Steel with In Situ Micro-Compression Testing

Additive manufacturing techniques are being used more and more to perform the precise fabrication of engineering components with complex geometries. The heterogeneity of additively manufactured microstructures deteriorates the mechanical integrity of products. In this paper, we printed AISI 316L stainless steel using the additive manufacturing technique of laser metal deposition. Both single-phase and dual-phase substructures were formed in the grain interiors. Electron backscatter diffraction and energy-dispersive X-ray spectroscopy indicate that Si, Mo, S, Cr were enriched, while Fe was depleted along the substructure boundaries. In situ micro-compression testing was performed at room temperature along the [001] orientation. The dual-phase substructures exhibited lower yield strength and higher Young’s modulus compared with single-phase substructures. Our research provides a fundamental understanding of the relationship between the microstructure and mechanical properties of additively manufactured metallic materials. The results suggest that the uneven heat treatment in the printing process could have negative impacts on the mechanical properties due to elemental segregation.

36 MATERIALS SCIENCE↗