Investigation of HIP Bonded AA6061 vs. AA6061 Cladding Interface as Functions of HIP Temperature and Cooling Rate
Presentation for conference
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
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Hip Abductor Strength Asymmetry: Relationship to Upper Extremity Injury in Professional Baseball Players
Background: Hip strength is an important factor for control of the lumbo-pelvic-hip complex. Deficits in hip strength may affect throwing performance and contribute to upper extremity injuries. Hypothesis: Deficits in hip abduction isometric strength would be greater in those who sustained an upper extremity injury and hip strength would predict injury incidence. Study Design: Prospective cohort study. Level of Evidence: Level 3. Methods: Minor League baseball players (n = 188, age = 21.5 ± 2.2 years; n = 98 pitchers; n = 90 position players) volunteered. Hip abduction isometric strength was assessed bilaterally with a handheld dynamometer in side-lying position, expressed as torque using leg length (N·m). Hip abduction strength asymmetry was represented by [(trail leg/lead leg) × 100]. Overuse or nontraumatic throwing arm injuries were prospectively tracked. Poisson regression models were used to estimate relative risk ratios associated with hip asymmetry; confounders, including history of prior overuse injury in the past year, were included. Results: Hip abduction asymmetry ranged from 0.05% to 57.5%. During the first 2 months of the season, 18 players (n = 12 pitchers) sustained an upper extremity injury. In pitchers, for every 5% increase in hip abduction asymmetry, there was a 1.24 increased risk of sustaining a shoulder or elbow injury. No relationship between hip abduction strength and injury was observed for position players. Conclusion: Hip abduction asymmetry in pitchers was related to subsequent upper extremity injuries. The observed risk ratio indicates that hip abduction asymmetry may contribute a significant but small increased risk of injury. Clinical Relevance: Hip abduction muscle deficits may affect pitching mechanics and increase arm stress. Addressing hip asymmetry deficits that exceed 5% may be beneficial in reducing upper extremity injury rates in pitchers.
Sport Sciences↗
Creep-Fatigue Properties of Additional 316H PM-HIP Materials Fabricated from Different Powder Compositions and Processing Routes
The process of powder metallurgy (PM) hot isostatic pressing (HIP) works by consolidating powdered materials at relatively high temperature and pressure to form near-net-shaped components. Ideally, PM-HIP production methods can reduce component lead time and improve designs for high-temperature reactors and/or microreactors. To introduce PM-HIP into Section III, Division 5 of the American Society of Mechanical Engineers Boiler and Pressure Vessel Code, it is necessary to show adequate material properties regarding creep, high-temperature low-cycle fatigue, and creep fatigue. However, prior work has shown that the creep-fatigue cycles to failure for PM-HIP 316H stainless steel are greatly reduced compared to the conventional, wrought product. This work continued creep-fatigue analysis on a 316H stainless steel with lower oxygen and nitrogen contents and at different HIP parameters than previously analyzed. The objective was to better understand what is causing the reduced PM-HIP 316H performance so improvements can be made PM-HIP 316H creep-fatigue lifetimes.
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Powder Metallurgy HIP Process Study and Mechanical Property Evaluations for IN740H
The effects of hot isostatic pressing (HIP) parameters and powder size distribution (PSD) on the resulting microstructure and properties of powder metallurgy (P/M) IN740H have been investigated. Properties can be substantially tailored through the appropriate management of these parameters. Applying a thermal presoak to the input powder prior to the sintering stage of HIP can significantly increase average grain size and coarse grain fraction, enabling a trade for improved creep resistance at the expense of tensile strength. Here, powder thermal presoak was found to have a larger impact on microstructure and properties than the use of a coarser PSD alone. Additionally, substantial grain growth and grain boundary migration is observed in P/M IN740H at HIP temperatures above 1260°C. Given its inherently finer grain size, P/M HIP IN740H typically outperforms its cast and wrought counterparts in tensile response. Creep life at 700–800°C was inferior to wrought due to PPBs coincident with grain boundaries which served as cavity nucleation sites, leading to lower creep ductility. The ability to adjust the microstructure toward a more balanced creep and tensile behavior allows P/M HIP IN740H to be considered for high-temperature applications in advanced ultra-supercritical steam and supercritical carbon dioxide power cycles.
36 MATERIALS SCIENCE↗
Comparing structure-property evolution for PM-HIP and forged alloy 625 irradiated with neutrons to 1 dpa
The nuclear power industry has growing interest in qualifying powder metallurgy with hot isostatic pressing (PM-HIP) to replace traditional alloy fabrication methods for reactor structural components. But there is little known about the response of PM-HIP alloys to reactor conditions. This study directly compares the response of PM-HIP to forged Ni-base Alloy 625 under neutron irradiation doses ~0.5–1 displacements per atom (dpa) at temperatures ranging ~321–385 °C. Post-irradiation examination involves microstructure characterization, ASTM E8 uniaxial tensile testing, and fractography. Up through 1 dpa, PM-HIP Alloy 625 appears more resistant to irradiation-induced cavity nucleation than its forged counterpart, and consequently experiences significantly less hardening. This observed difference in performance can be explained by the higher initial dislocation density of the forged material, which represents an interstitial-biased sink that leaves a vacancy supersaturation to nucleate cavities. These findings show promise for qualification of PM-HIP Alloy 625 for nuclear applications, although higher dose studies are needed to assess the steady-state irradiated microstructure.
21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
MRP: Qualification of Powder Metallurgy Hot Isostatic Pressed (PM HIP) Materials for Elevated-Temperature Nuclear Construction
PM HIP is a mature technology that offers many advantages that are attractive to the microreactor industry. The elevated-temperature creep-fatigue properties of the PM HIP 316H SS bar that has been characterized are reduced compared to the wrought material. Work will be carried out in fiscal year 2022 to identify the mechanisms responsible for the reduced creep-fatigue properties. Confirmatory testing of optimized material will be conducted to demonstrate long-term PM HIP properties comparable to the wrought-product form. The lessons learned for PM HIP 316H SS will be applied to the procurement and confirmatory testing of PM HIP Alloy 800H.
316H stainless steel↗
A comparison of plastic and visco-plastic constitutive models for accurate predictions in PM-HIP
Powder metallurgy hot isostatic pressing (PM-HIP) is an advanced manufacturing process that can efficiently produce near net shape parts with high material utilization and uniform microstructures. While the PM-HIP process is used frequently to produce small-scale components, its application to large-scale components is still limited due to inadequate understanding of its complex processes that cause unpredictable post-HIP shape distortions. A computational model can be a cost-effective alternative to exhaustive experimentation required to understand the PM-HIP process fully. Therefore, we present a comparison of plastic and visco-plastic models that are frequently used to model the PM-HIP process. We show that the predictions of powder densification behavior and shape distortions obtained from both the models are similar under most conditions and agree well with experimental observations.
Sarkar, Subrato [ORNL]↗
Experiment design for the neutron irradiation of $\mathrm{PM-HIP}$ alloys for nuclear reactors
Here, this article describes the design of an Advanced Test Reactor (ATR) drop-in neutron irradiation experiment aiming to directly compare the performance of nuclear structural alloys fabricated by powder metallurgy with hot isostatic pressing (PM-HIP) against conventional casting or forging. There is growing interest in PM-HIP alloys for nuclear applications because of their microstructural uniformity, superior mechanical properties, and reduced dependence on welding and machining, compared to cast/forged alloys. Nuclear code-qualification of PM-HIP alloys requires neutron irradiation testing to demonstrate performance under relevant conditions. In this experiment, six nuclear structural alloys were irradiated: Ni-based alloys 625 and 690, Grade 91 ferritic steel, SA508 pressure vessel steel, and 304L and 316L austenitic stainless steels. The experiment is assembled into seven capsules in four test trains and irradiated in three ATR inboard A positions. Both the PM-HIP and cast/forged versions of each alloy were irradiated under nearly identical conditions for comparative purposes, to target doses of 1 ± 0.2 and 3 ± 0.2 dpa at temperatures of 300 ± 50 °C and 400 ± 50 °C. A thorough description of the experiment design and thermal, structural and neutronic analyses performed to ensure the targeted irradiation conditions are met is provided. Specimens were configured as small disks, compact tension specimens and tensile bars to facilitate post-irradiation examination (PIE) that will include mechanical testing, microstructure characterization, and fracture toughness testing. Given the considerations for ASTM standardized mechanical testing, comparative fluence and temperature across specimen pairs, and comprehensive PIE planning herein, this work serves as a template for future nuclear materials qualification experiment designs.
21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
Low Cost HIP Fabrication of Advanced Power Cycle Components and PM/Wrought Inconel 740H Weld Development (Final Technical Report)
The objective of this Phase 1 project is to demonstrate the feasibility of structures and components for advanced fossil energy power cycle by fusion welding powder metallurgy (PM) based near net shape (NNS) hot isostatic pressing (HIP) Nickel superalloy Inconel 740H (IN740H) components to wrought IN740H components. The outcome of the project includes a prototype pipe elbow demonstration of the NNS HIP process using IN740H powder, an initial assessment of IN740H PM/wrought weldability, and a manufacturing and capital cost analysis of IN740H NNS HIP components for advanced ultra-super critical steam (AUSC) power plants. The anticipated value proposition of NNS HIP manufacturing is ~50% cost reduction of large complex components in AUSC or super-critical carbon dioxide (sCO2) power cycles. This document is a final technical report for the project, covering efforts conducted from October 2019 to June 2021.
20 FOSSIL-FUELED POWER PLANTS↗
Atomistic simulations to reveal HIP-bonding mechanisms of Al6061/Al6061
Molecular dynamics simulations were employed to understand the diffusion bonding process during hot isostatic pressing (HIP) of Al6061/Al6061 alloy. Simulations of the HIP process reveal atomistic phenomena that are difficult or unlikely to be observed experimentally and provide useful insights into the mechanism of diffusion and bonding. Here, the results reveal that at the start of the HIP process, a massive incursion of oxygen atoms occurs from the pre-existing γ-Al 2 O 3 to the 6061 region across the interphase interface. These oxygen atoms interact with the enriched Mg atom layer present at the existing γ-Al 2 O 3 and 6061 matrix to form a secondary complex Mg 2 Al 2 O 5 phase. Diffusion calculations also show that transport of atoms due to the applied pressure is 4–5 orders of magnitude higher than would occur in the absence of HIP conditions. The Mg 2 Al 2 O 5 phase also provides efficient pathways for the rapid transport of Mg atoms. Because of the higher diffusion coefficients observed for Mg within the phase, Mg atoms can move more swiftly compared to their diffusion within other phases such as γ-Al 2 O 3 . This accelerated mobility facilitates the rapid movement of Mg atoms across the interface, leading to changes in the local composition and the potential growth of the Mg 2 Al 2 O 5 phase.
36 MATERIALS SCIENCE↗
Hiding-in-Plain-Sight (HiPS) Attack on CLIP for Targetted Object Removal from Images
Machine learning models are known to be vulnerable to adversarial attacks, but prior works have mostly focused on single-modalities. With the rise of large multi-modal models (LMMs) like CLIP, which combine vision and language capabilities, new vulnerabilities have emerged. However, these multimodal targeted attacks aim to completely change the model's output to what the adversary wants. In many realistic scenarios, an adversary might seek to make only subtle modifications to the output, so that the changes go unnoticed by downstream models or even by humans. We introduce Hiding-in-Plain-Sight (HiPS) attacks, a novel class of adversarial attacks that subtly modifies model predictions by selectively concealing target object(s), as if the target object was absent from the scene. We propose two HiPS attack variants, HiPS-cls and HiPS-cap, and demonstrate their effectiveness in transferring to downstream image captioning models, such as CLIP-Cap, for targeted object removal from image captions.
Daw, Arka [ORNL] (ORCID:0009000633191271)↗
A comparative study on the physicochemical characteristics of nanoparticles released in vivo from CoCrMo tapers and cement–stem interfaces of total hip replacements
The good biocompatibility and corrosion resistance of the bulk CoCrMo alloy has resulted in it being used in the manufacture of implants and load bearing medical devices. These devices, however, can release wear and corrosion products which differ from the composition of the bulk CoCrMo alloy. The physicochemical characteristics of the particles and the associated in vivo reactivity are dictated by the wear mechanisms and electrochemical conditions at the sites of material loss. Debris released from CoCrMo hip bearings, taper junctions, or cement–stem interfaces can, therefore, have different chemical and morphological characteristics, which provide them with different in vivo toxicities. Here, we propose to assess and compare the characteristics of the particles released in vivo from CoCrMo tapers and cement–stem interfaces which have received less attention compared to debris originating from the hip bearings. The study uses state–of–art characterization techniques to provide a detailed understanding of the size, morphology, composition, and chemistry of the particles liberated from the wear and corrosion flakes from revised hip replacements, with an enzymatic treatment. The phase analyses identified Cr 2 O 3 nanoparticles released from tapers and cement–stem interfaces, whose composition did not vary with origin or particle morphology. The size distributions showed significantly smaller particles were released from the stems, compared to the particles originating from the corresponding tapers. Furthermore, the investigation demonstrates that the tribocorrosive processes occurring at the taper and stem interfaces both result in Cr 2 O 3 nanoparticle formation.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Near-Net-Shape HIP Manufacturing for sCO2 Turbomachinery Cost Reduction
sCO2 turbomachinery that operates above 650°C requires the use of γ' strengthened Ni-based superalloys, leading to high cost and barrier of market adoption. Near-net-shape (NNS) HIP manufacturing with 282® alloy powder is being developed for sCO2 turbine components, with a significant estimated cost reduction. Tensile, creep, low cycle fatigue properties of argon gas atomized and plasma atomized powders were evaluated and compared to sand cast HAYNES® 282®. While tensile strength and fatigue life outperformed sand cast material, a 10~25% debit in the creep stress capability was observed due to the fine grain size and presence of prior particle boundaries (PPBs). Finite element model calibrated by powder rheological properties accurately predicted the nonuniform shrinkage during HIP, providing HIP tooling design to achieve the target dimension. A 20 lbs. turbine nozzle ring was successfully demonstrated within 0.01 inch dimensional tolerance at the vanes. A 1700lbs. turbine casing with complex internal struts and manifolds was also demonstrated being close to the target dimension.
14 SOLAR ENERGY↗
Microstructure characteristics of LPBF&HIP fabricated graded composite transition joint between ferritic steel and austenitic stainless steel
Graded composite transition joints (GCTJs) offer a promising alternative to conventional dissimilar metal welds (DMWs) by enabling smooth compositional and microstructural transitions. However, GCTJs fabricated solely through additive manufacturing (AM) face challenges such as heat accumulation, complex parameter control, and elemental segregation. In this study, we propose a novel approach that relies on AM to design a spatially graded structure in one alloy and then employs hot isostatic pressing (HIP) as a diffusion bonding method to join it with a second alloy. Here, this method combines the flexibility of AM with the powder net-shaping advantage of HIP. Specifically, a series of closely packed austenitic stainless steel 304 conical structures were printed using laser powder bed fusion (LPBF) and then combined with ferritic steel P91 powder via HIP. By using electron backscatter diffraction (EBSD), electron probe microanalysis (EPMA), and transmission electron microscopy (TEM) techniques, the microstructure characteristics of the GCTJ of 304&P91, especially the interdiffusion zone (IDZ), have been systematically investigated. The microstructure at the interface transitions from austenite-ferrite (A+F) to austenite-martensite-ferrite (A+M+F), and finally to martensite-ferrite (M+F) due to diffusion. Additionally, the diffusion width between 304 and P91 increases with the volume fraction of P91. This unique design also ensures a gradual transition in both hardness and thermal expansion coefficient from 304 to P91, thereby enabling a smooth gradient in functional properties. Overall, this study proposes a novel approach for fabricating GCTJs and contributes to advancing design concepts in the field of dissimilar metal joining.
Additively manufacturing (AM)↗
Correlation between Interface Microstructure and Bond Strength of Al6061/Al6061 HIP-Bonded Plates for Fuel Cladding Application
The effects of hot isostatic pressing (HIP) processing parameters on microstructure and bond strength of Al6061/Al6061 plate interfaces were systemically investigated at the micro- and nanoscale. The HIP bonding of the two aluminum plates was performed at four temperatures: 350°C, 400°C, 450°C, and 560°C. The results reveal the formation of micron scaled Mg 2 Si precipitate and uniform nano scaled Mg 2 Al 2 O 5 oxide at the interface. The formation of Mg 2 Al 2 O 5 is closely associated with the fast bulk diffusion of Mg from the Al matrix to the amorphous Al 2 O 3 /Al interface and subsequent reaction between Mg and Al 2 O 3 . Finally, the highest and lowest bond strengths were observed in samples HIP bonded at 450°C and 350°C, respectively.
36 MATERIALS SCIENCE↗
Processing, Microstructure, and Properties of Bimetallic Steel-Ni Alloy Powder HIP
This work explores technical feasibility in hot isostatic pressing (HIP) manufacturing of an integral bimetallic component using steel and Ni alloy powder for supercritical carbon dioxide (sCO2) turbomachinery. Lab-scale bimetallic HIP specimens using HAYNES® 282® and SS316L or SS415 powder are investigated in powder configuration, heat treatment, microstructure, and tensile properties up to 400 °C. Interdiffusion profiles at dissimilar alloy interfaces caused by HIP cycle is predicted by DICTRA simulations and validated by electron probe microanalysis (EPMA). The interdiffusion distance of most elements is around 100 μm, while C and N have a higher interdiffusion distance. Dense distribution of Ti-rich carbonitrides and alumina particles are found to decorate prior particle boundaries near joining interface on the 282 side, affecting tensile strength across interface as well as tensile failure location. A higher amount of excessive carbonitride formation near interface is observed in SS316L/282 than in SS415/282, which is consistent with the predicted greater degree of interdiffusion effect in SS316L/282. Typical HAYNES® 282® heat treatment condition is applicable to 282/SS316L and 282/SS415 combinations, resulting in a higher strength than cast CF8M and CA6NM. A pilot-scale bimetallic SS415/282 pipe is then demonstrated to show the promise of scaleup.
36 MATERIALS SCIENCE↗
Pseudo-Hot-Isostatic Pressing (P-HIP)
Researchers at Los Alamos National Laboratory developed a technology to produce high performance ceramic or metal with a combination of major key properties such as versatile-complicated shape, high density, uniform density distribution, and minimal amounts of starting material. The novel pseudo-hot-isostatic-pressing (P-HIP) uses graphite or boron nitride flakes as the stress transmission media to transmit stress instead of the conventional solid graphite punch. The graphite and boron nitride flakes are solid lubricants and can slide among one another to re-distribute the stress from high stress concentration area to the low stress concentration areas, resulting in a self-stress-relief action. This innovative P-HIP enables the manufacturing of complicated shapes with near-net-shape capability while minimizing the energy used and reducing waste. This is a revolutionary breakthrough to the ceramics and powder metallurgy industries.
36 MATERIALS SCIENCE↗
SCExAO/MEC and CHARIS Discovery of a Low-mass, 6 au Separation Companion to HIP 109427 Using Stochastic Speckle Discrimination and High-contrast Spectroscopy
We report the direct imaging discovery of a low-mass companion to the nearby accelerating A star, HIP 109427, with the Subaru Coronagraphic Extreme Adaptive Optics (SCExAO) instrument coupled with the Microwave Kinetic Inductance Detector Exoplanet Camera (MEC) and CHARIS integral field spectrograph. CHARIS data reduced with reference star point spread function (PSF) subtraction yield 1.1–2.4 μm spectra. MEC reveals the companion in Y and J band at a comparable signal-to-noise ratio using stochastic speckle discrimination, with no PSF subtraction techniques. Combined with complementary follow-up L {sub p} photometry from Keck/NIRC2, the SCExAO data favors a spectral type, effective temperature, and luminosity of M4–M5.5, 3000–3200 K, and log{sub 10}(L/L{sub ⊙})=−2.28{sub −0.04}{sup +0.04}, respectively. Relative astrometry of HIP 109427 B from SCExAO/CHARIS and Keck/NIRC2, and complementary Gaia–Hipparcos absolute astrometry of the primary favor a semimajor axis of 6.55{sup +3.0} {sub −0.48} au, an eccentricity of 0.54{sub −0.15}{sup +0.28}, an inclination of 66.7{sub −14}{sup +8.5} degrees, and a dynamical mass of 0.280{sub −0.059}{sup +0.18} M {sub ⊙}. This work shows the potential for extreme AO systems to utilize speckle statistics in addition to widely used postprocessing methods to directly image faint companions to nearby stars near the telescope diffraction limit.
46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗