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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 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS2019

Post-Test Microstructural Analysis of Particle Impact-Tested Wrought Inconel, Additively Manufactured Inconel and Wrought Monel Targets

Particle impact testing in high pressure oxygen was performed to evaluate ignition susceptibility of Inconel 718 and Monel 400. Sapphire particles (1.5-mm diameter) under high pressure oxygen, travelling at hypersonic speeds, made impact with metal targets, resulting in surface indentations. This report details the post-test characterization of impact craters observed on three metallic target samples: wrought nickel-based superalloy Inconel 718 (IN718), additively manufactured Inconel 718 (AM-IN718) and nickel-copper alloy, Monel 400.

Ochoa, Ngozi C.↗
DOE OSTI2026

Linking microstructure to creep behavior in vertically and horizontally built LPBF Haynes 282 compared with wrought material via θ -projection

Laser Powder Bed Fusion (LPBF) has emerged as a promising route for fabricating intricate geometries in high-performance alloys. Haynes 282 (H282) is a strong candidate for applications such as heat exchangers or engines due to its excellent creep strength and thermal stability; however, the long-term creep behavior of LPBF-processed H282 remains poorly understood. In this study, the θ -projection method is used to analyze and extrapolate the creep behavior of vertically built LPBF, horizontally built LPBF, compared to wrought H282 tested at 816 °C. Vertically built LPBF H282 exhibits the lowest minimum creep rate (MCR), while the horizontally built condition shows a higher MCR comparable to that of wrought H282. Despite these differences, both LPBF conditions exhibit significantly shorter rupture life and reduced rupture strain than the wrought material, with the most severe degradation observed in the horizontal builds, consistent with an earlier onset of tertiary creep and accelerated strain-rate evolution. Microstructural characterization reveals that both LPBF and wrought H282 exhibit abundant twin-related boundary character; however, their grain boundary topologies differ markedly. The wrought alloy contains a higher fraction of low-angle grain boundaries and continuous twin lamellae, whereas the LPBF microstructure is characterized by a suppressed low-angle boundary population and fragmented twin-related boundaries embedded within irregular high-angle grain boundary networks. Fractographic analysis further reveals predominantly intergranular cracking in LPBF H282, accompanied by grain-boundary-decorated carbides, Al 2 O 3 inclusions, and high-aspect-ratio pores. These results demonstrate that grain boundary topology, rather than minimum creep rate alone, plays a critical role in governing creep damage accumulation and rupture behavior in LPBF and wrought H282.

Creep↗
DOE OSTI2024

High-Temperature Oxidation Behavior of Wrought and Additive Manufactured Ni-based Alloys in Direct-Fired Supercritical CO2 Power Cycle Environments

Materials selection is a key concern for corrosion resistance in elevated temperature and pressure direct-fired supercritical CO2 (sCO2) power cycles. Herein, the wrought product form of alloy H282, as well as several additional nickel-based commercial alloys (230, 263, 617, 625, 740H), were exposed to direct-fired supercritical CO2 conditions (95CO2 – 4H2O – 1O2) at 750 °C and 20 MPa for over 2,000 h. Additionally, additive manufactured (AM) 282 produced by laser powder bed fusion (LPBF) were also included in the exposures. This paper focuses primarily on the differences observed in the degradation behavior of the wrought and additively manufactured materials. AM samples in the as-printed state were found to form less protective oxide scales resulting in higher oxidation rates compared to wrought samples. However, applying a 600 grit surface finish to the AM samples modified the oxidation behavior to closely resemble that of the wrought material. The AM samples formed Mo-rich carbides in the alloy beneath the oxide following sCO2 exposure, implying potentially higher levels of carbon uptake relative to the wrought material. Conversely, the AM samples seemed to be less affected by water-assisted oxide volatilization compared to the wrought material. The results are discussed in terms of the potential compatibility issues that may arise when using Ni-based alloys in the hot portions of direct-fired sCO2 power cycles, particularly in the case of thin-walled components.

Carney, Casey↗
DOE OSTI2026

A comparison of wrought and powder metallurgical FeCrAl claddings under simulated LWR accident transients

Iron-chromium-aluminum (FeCrAl) alloys are potential accident tolerant fuel (ATF) cladding candidates for light-water reactors but are difficult to fabricate as thin-walled tubes via conventional cast-and-wrought routes. Powder metallurgy (PM) offers a manufacturing alternative with improved compositional control, but its transient accident performance has not been directly benchmarked against wrought variants. This study evaluates the burst behavior of commercially developed PM-processed FeCrAl alloys, PM-C26M (Fe-12Cr-6Al-2Mo) and the high precipitate density FA-SMT (Fe-22Cr-5Al-3Mo), under simulated light-water reactor accident transient conditions. Burst testing was conducted using the Severe Accident Test Station with heating rates of 5 °C/s and 50 °C/s and internal pressures ranging from 25 MPa to 100 MPa. PM-C26M reproduced wrought C26M burst behavior within 7–37 °C across the stress range, indicating that PM processing does not compromise transient strength. FA-SMT exhibited markedly higher burst temperatures and reduced heating-rate sensitivity, consistent with its engineered precipitate strengthening. FA-SMT rupture exhibited axial "unzipping" rather than the lateral tearing characteristic of PM- and wrought C26M. Post-test EBSD and fractography indicate that this behavior is strongly correlated with strain-gated intergranular void nucleation associated with the dense precipitate architecture of FA-SMT, a response absent in the comparatively clean PM-C26M matrix and consistent with rupture morphologies reported for oxide-dispersion strengthened (ODS) FeCrAl of similar base-matrix chemistry to PM-C26M. These findings highlight the potential of powder metallurgy as a viable fabrication route for ATF claddings from an accident performance standpoint.

Bell, Sam [ORNL] (ORCID:0000000251905657)↗
DOE OSTI2026

Accelerated creep profiling: a high-throughput thermal- and stress-gradient approach applied to additive and wrought stainless steel

Here, this study investigates logarithmic creep behavior at temperatures near room temperature in wrought and additively manufactured (AM) 316 L austenitic stainless steel. A novel high-throughput (HiTp) methodology employed thermal gradients to obtain stress- and temperature-dependence of creep behavior. The findings, based on 104 two-week creep tests, reveal significant differences in creep response between wrought and AM materials. Compared to the wrought material, the AM material exhibited a higher activation energy and a lower activation volume. These differences were attributed to the materials’ distinct microstructural features, e.g., dislocation cell structures and precipitate distributions, which alter the susceptibility to dislocation glide creep, particularly at stresses below the yield stress. The HiTp methodology provides both an accelerated determination of low-temperature creep mechanisms, offering critical data for the design and optimization of alloys in near-ambient, high stress applications.

316 L Stainless steel↗
DOE OSTI2022

A Comparative Tribo-Mechanical Behavior Analysis of Laser Cladded Nitronic 60 Coating Against Wrought Nitronic 60 Alloy

In this study the tribological and mechanical behavior of a laser cladded Nitronic 60 coating on maraging steel is compared to that of a wrought Nitronic 60 alloy. A multi-layer Nitronic 60 coating was deposited using laser directed energy deposition, and its microstructure, porosity, and microhardness were characterized. The microhardness of the coated region in the laser cladded Nitronic 60 varied between 270-300 HV whereas that for wrought form was 230 HV. Controlled tribological tests under motor oil lubricated conditions were conducted at both room and elevated temperatures. The laser cladded Nitronic coating exhibited poorer wear resistance at room temperature but higher wear resistance at elevated temperature as compared to the wrought Nitronic alloy. Severe plastic deformation and fracture was observed on the laser cladded coating after the wear tests at both temperatures. Wear mechanisms were investigated based on the morphological and compositional characterization of the wear tracks.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Evaluation of the Mechanical Properties of Cast and Wrought CF8C-Plus Relevant to ASME Code Case Qualification

The mechanical behavior of a cast form of an advanced austenitic stainless steel, CF8C-Plus, is compared with that of its wrought equivalent in terms of both tensile and creep-rupture properties and estimated allowable stress values for pressurized service at temperatures up to about 850°C. A traditional Larson-Miller parametric model is used to analyze the creep-rupture data and to predict long-term lifetimes for comparison of the two alloy types. The cast CF8C-Plus exhibited lower yield and tensile strengths, but higher creep strength compared to its wrought counterpart. Two welding methods, shielded-metal-arc welding (SMAW) and gas-metal-arc welding, met the weld qualification acceptance criteria in ASME BPVC Section IX for the cast CF8C-Plus. However, for the wrought CF8C-Plus, while SMAW and gas-tungsten-arc welding passed the tensile acceptance criteria, they failed the side bend tests due to lack of fusion or weld metal discontinuities.

Chen, Xiang↗
DOE OSTI2019

Machining of Wrought Alloy 316L Specimens to Evaluate Elevated-Temperature Fatigue and Creep-Fatigue Properties

At the 2019 GAIN Microreactors workshop, a need to fabricate microreactor components through advanced manufacturing (AM) was conveyed by microreactor developers. Powder metallurgy (PM) hot isostatic pressing (HIP) is more mature than other AM techniques and thus more readily deployable in the near term. The elevated-temperature cyclic properties of materials manufactured by PM HIP, however, have not been established. Work is currently in progress to evaluate the elevated-temperature cyclic properties of Alloy 316L manufactured by PM HIP. These properties need to be compared to those of wrought Alloy 316L in order to understand the effect of PM HIP. Therefore, wrought Alloy 316L testing at the same conditions as those tested for the PM HIP is necessary. This statement of work provides instructions and requirements for the machining of wrought Alloy 316L specimens.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

High-Temperature Oxidation Behavior of Wrought and Additive Manufactured Alloys in Direct-Fired Supercritical CO2 Power Cycle Environments

Materials selection is a key concern for corrosion resistance in elevated temperature and pressure direct-fired supercritical CO2 (sCO2) power cycles. The effect of elevated pressure on corrosion resistance can be critical, as impurities within the supercritical fluid such as H2O and O2 can have additional corrosion effects than found at ambient pressure conditions. Several wrought nickel-based commercial alloys (230, 263, 282, 617, 625, 740H) were exposed to direct-fired conditions (95CO2 – 4H2O – 1 O2) at 750 °C at both atmospheric pressure (0.1 MPa) and supercritical conditions (20 MPa) for over 2,000 h. Additionally, additive manufactured (AM) 282 produced by laser powder bed fusion (LPBF) were also included in the exposures. Supercritical conditions affected the oxidation behavior of several alloys. Most notably, water-vapor assisted Cr-oxide volatilization was observed at 750 °C supercritical conditions. Many alloys did not form sufficient protective Cr-oxide scales at supercritical conditions, leading to increased oxidation at elevated pressure. Differences in oxidation behavior were also observed for 282 AM samples compared to their wrought counterparts, with the differences also dependent on the LPBF build parameters and post-production treatments (heat treatment and surface finishing procedures). The AM samples formed Mo-rich carbides in the alloy beneath the oxide following sCO2 exposure, implying potentially higher levels of carbon uptake relative to the wrought

Carney, Casey↗
DOE OSTI2021

An investigation into the effects of cyclic strain rate on the high cycle and very high cycle fatigue behaviors of wrought and additively manufactured Inconel 718

Additive Manufacturing (AM) has increasingly been used to fabricate parts in aerospace applications, which may require service lives beyond ten-million cycles due to the imposed high loading frequencies. Understanding the very high cycle fatigue (VHCF) behavior of these additive manufactured (AM) parts is an important step towards their design and qualification processes. This study focuses on the high cycle fatigue (HCF) and VHCF behaviors of both wrought and laser beam-powder bed fusion (LB-PBF) fabricated Inconel 718 in machined/polished surface condition, emphasizing on the influence of test frequency (i.e., cyclic strain rate). Uniaxial, fully-reversed force- and stress-controlled fatigue tests were conducted utilizing a servo-hydraulic and an ultrasonic test system operating at 5 Hz and 20 kHz, respectively, on wrought as well as LB-PBF vertically and diagonally built specimens. Fatigue cracks in the majority of the specimens were found to initiate from intra-granular slip bands near or at the surface, which gives rise to strong anisotropy in fatigue resistance in LB-PBF specimens due to the presence of columnar grains along the build directions. Longer fatigue lives were obtained at 20 kHz, which was ascribed to possibly lower-than-intended stresses applied in the ultrasonic tests. The corrected stress-life fatigue data at 20 kHz were found to converge to the one obtained from conventional testing at 5 Hz, implying no effect of cyclic strain rate on the fatigue behavior of Inconel 718 regardless of the fabrication process. The findings of this work confirm the use of ultrasonic fatigue testing to expedite generation of AM materials data to keep up with the current demand; however, the applied stress may need to be corrected.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Machinability comparison of additively manufactured and traditionally wrought Ti-6Al-4V alloys using single-point cutting

Post-machining is often needed to provide high dimensional accuracy and fine surface finish for additively manufactured Ti-6Al-4V (Ti64). The material inhomogeneity, such as pores and microstructures, can affect the machining behavior of this already difficult-machine alloy. This study adopts a holistic approach to compare the machinability of additively manufactured and traditionally wrought Ti64 in terms of key machining factors, including forces, temperature, and vibration and the major machining outcomes including tool life, surface finish, and dimensional accuracy. Stress-relief annealing is applied to each of the part conditions as a secondary variable to observe the additional effects. The results show that AM is not particularly more difficult to machine in terms of cutting force and temperature, but it creates high cutting vibrations across a wide range of frequencies (to and over 5 kHz). The high vibrations do not lead to worse surface finish or dimensional accuracy but tend to worsen the tool life by chipping off the cutting edge. The vibration can be attributed to the brittle martensitic microstructure found in additively manufactured Ti64, which is also evidenced by the more serrated chips. Stress-relieving is found to change the microstructure and reduce the level of vibration to that of the wrought counterpart.

36 MATERIALS SCIENCE↗
DOE OSTI2024

On the role of geometrically necessary dislocations in void formation and growth in response to shock loading conditions in wrought and additively manufactured Ta

This study investigates the role of geometrically necessary dislocations (GNDs) and microstructure on void nucleation and growth in wrought and additively manufactured (AM) tantalum subjected to high-strain rate loading. Multi-modal 3D data was collected using TriBeam tomography to calculate GND densities and their spatial relationship to voids. A microstructural comparison between the wrought and AM samples identified distinct void shapes and locations, with intragranular voids and more spherical voids frequently observed in the AM dataset. Results indicate that voids preferentially form at both high-angle grain boundaries and low-angle subgrain boundaries, the latter of which are frequently observed in the AM material. Through a radial distribution analysis of all voids in the datasets, significant GND localization to near-void-surface regions was observed in both samples. 3D crystal plasticity simulations were employed to extend the experimental observations, revealing higher void growth rates in [111] oriented grains when compared to [001] grains. The simulations also suggest that GNDs can be generated as part of the void growth process, with more GND accumulation for growth in a [111] grain than a [001] grain. These findings provide valuable insights into the links between nanoscale void nucleation, mesoscale void growth, and microstructural effects in dynamically loaded tantalum.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Measurement of the Hugoniot and shock-induced phase transition stress in wrought 17-4 PH H1025 stainless steel

Uniaxial strain, reverse-ballistic impact experiments were performed on wrought 17-4 PH H1025 stainless steel, and the resulting Hugoniot was determined to a peak stress of 25 GPa through impedance matching to known standard materials. The measured Hugoniot showed evidence of a solid–solid phase transition, consistent with other martensitic Fe-alloys. The phase transition stress in the wrought 17-4 PH H1025 stainless steel was measured in a uniaxial strain, forward-ballistic impact experiment to be 11.4 GPa. Linear fits to the Hugoniot for both the low and high pressure phase are presented with corresponding uncertainty. The low pressure martensitic phase exhibits a shock velocity that is weakly dependent on the particle velocity, consistent with other martensitic Fe-alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Analysis of Pitting Corrosion on Wrought and Additively Manufactured 316L Stainless Steel in Atmospheric Environments

Additive manufacturing of metal components enables rapid fabrication of complex geometries. However, metal additive manufacturing also introduces new morphological and microstructural characteristics which might be detrimental to component performance. Here we report the pitting corrosion properties of wrought and additively manufactured 316L stainless steel after atmospheric exposure to coastal environments and laboratory-created environments. Qualitative visualization in combination with quantitative analysis of resulting pits provided an in-depth understanding of pitting differences between wrought and additively manufactured 316L stainless steel and between coastal and laboratory-based exposure. Optical and scanning electron microscopy were utilized for visualization, while white light interferometry measured pits across approximately 5mm x 5mm areas on each sample. Post-processing of the interferometry data enables quantification of pitting attack for each sample in terms of both pit depth and pit volume. The pitting analysis introduced herein offers a new technique to compare pitting attack between different manufacturing processes and materials.

36 MATERIALS SCIENCE↗
NASA NTRS1972

Further development and characterization of VM-103, a NASA wrought cobalt base alloy

The data obtained during this and previous programs indicate that the VM-103 has useful strength at temperatures as high 2200 F (1204 C), and can be considered as an alternate for other wrought superalloys such as L-605. The addition of 10 percent nickel to the standard composition improves both the hot and cold fabricability, ductility, impact strength, and metallurgical stability, while it only slightly reduces strength properties. Electroslag re-melting was effective in significantly increasing the fabricability of vacuum induction method VM-103, both with and without the 10 percent nickel addition. A specification for wrought VM-103 was developed and is included. Although thermomechanical processing improves lower temperature properties, no improvement occurs at temperatures at or above 2000 F (1093 C).

Harlow, R. A.↗
NASA NTRS1992

Thermomechanical and bithermal fatigue behavior of cast B1900 + Hf and wrought Haynes 188

A thermomechanical fatigue (TMF) high-temperature life prediction method has been evaluated using the experimental data. Bithermal fatigue (BTF), bithermal creep-fatigue (BTC-F), and TMF experiments were performed using two aerospace structural alloys, cast B1900 + Hf and wrought Haynes 188. The method which is based on the total strain version of strain range partitioning and unified cyclic constitutive modeling requires, as an input, information on the flow and failure behavior of the material of interest. Bithermal temperatures of 483 and 871 C were used for the cast B1900 + Hf nickel-base alloy and 316 and 760 C for the wrought Haynes 188 cobalt-base alloy. Maximum and minimum temperatures were also used in both TMF and BTF tests. Comparisons were made between the results of these tests and isothermal tensile and fatigue test data obtained previously. Qualitative correlations were observed between tensile and isothermal fatigue tests.

Halford, G. R.↗
NASA NTRS1993

Microstructural stability of wrought, laser and electron beam glazed NARloy-Z alloy at elevated temperatures

Microstructure of wrought, laser, and electron-beam glazed NARloy-Z(Cu-3 wt.% Ag-0.5 wt.% Zr) was investigated for thermal stability at elevated temperatures (539 to 760 C (1,100 to 1,400 F)) up to 94 h. Optical and scanning electron microscopy and electron probe microanalysis were employed for studying microstructural evolution and kinetics of precipitation. Grain boundary precipitation and precipitate free zones (PFZ's) were observed in the wrought alloy after exposing to temperatures above 605 C (1,120 F). The fine-grained microstructure observed in the laser and electron-beam glazed NARloy-Z was much more stable at elevated temperatures. Microstructural changes correlated well with hardness measurements.

Singh, J.↗
NASA NTRS1996

Testing of Wrought Iridium/Chemical Vapor Deposition Rhenium Rocket

A 22-N class, iridium/rhenium (Ir/Re) rocket chamber, composed of a thick (418 miocrometer) wrought iridium (Ir) liner and a rhenium substrate deposited via chemical vapor deposition, was tested over an extended period on gaseous oxygen/gaseous hydrogen (GO2/GH2) propellants. The test conditions were designed to produce species concentrations similar to those expected in an Earth-storable propellant combustion environment. Temperatures attained in testing were significantly higher than those expected with Earth-storable propellants, both because of the inherently higher combustion temperature of GO2/GH2 propellants and because the exterior surface of the rocket was not treated with a high-emissivity coating that would be applied to flight class rockets. Thus the test conditions were thought to represent a more severe case than for typical operational applications. The chamber successfully completed testing (over 11 hr accumulated in 44 firings), and post-test inspections showed little degradation of the Ir liner. The results indicate that use of a thick, wrought Ir liner is a viable alternative to the Ir coatings currently used for Ir/Re rockets.

Reed, Brian D.↗