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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 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Orientation-selected micro-pillar compression of additively manufactured 316L stainless steels: Comparison of as-manufactured, annealed, and proton-irradiated variants

In this work, irradiation response and deformation mechanisms of additively manufactured (AM) 316L stainless steel were studied by atomic scale characterization and micro-pillar compression. The AM 316L stainless steels were fabricated by direct energy deposition, a laser-based additive manufacturing process. Irradiation with 2 MeV protons at 360°C was performed to create ~1.8 displacements-per-atom (dpa) damage in AM 316L. Deformation behaviors of the as-manufactured, annealed, and proton-irradiated variants were studied, focusing on the effects of manufacturing-induced pores, residual stress, and irradiation-introduced defects (dislocation loops and voids). Micro-pillars were prepared from grains of pre-selected orientation, avoiding contributions of grain boundaries and allowing determination of resolved shear stress on {111} glide planes. Transmission electron microscopy was used to characterize the pre- and post-deformation microstructure. It was found that in the as-manufactured alloy variant, moving dislocations were the major deformation carrier, with noticeable blocking by fabrication-induced pores, In the annealed variant, hardness was reduced, and deformation was also accomplished by dislocation gliding. In the proton-irradiated variant, significant twinning was observed. Comparing measured resolved shear stress and predicted critical stress for dislocation dissociation, we conclude that irradiation hardening became high enough to activate twinning. Therefore, the deformation mechanism changes from dislocation gliding to twinning. The study is important for both processing optimization and performance evaluation of AM alloys for reactor applications.

36 MATERIALS SCIENCE↗
NASA NTRS2017

Cryogenic Thermal Emittance Measurements on Small-Diameter Stainless Steel Tubing

The Mid Infrared Instrument aboard the James Webb Space Telescoep includes a mechanical cryocooler which cools its detectors to their 6 K operating temperature. The refrigerant flows through several meters of approximately 2 mm diameter 304L stainless steel tubing, with some sections gold plated, and some not, which are exposed to their environment. An issue of water freezing onto the tube surfaces is mitigated by a running a warm gas through the lines to sublimate the water. To model the effect of this process on nearby instruments, an accurate measure of the tube emittance is needed. Previously we reported the abosprtance of the gold plated stainless steel tubing as a function of source temperature (i.e. its environment). In this work the thermal emittance of the uncoated tubing is measured as a function of its temperature between 100 and 300 K. This value leads to an accurate prediction of the minimum length of time required to thermally recycle the system. We report the technique and present the results.

cryogenic↗
DOE OSTI2020

Influence of defect characteristics on tensile deformation of an additively manufactured stainless steel: Evolutions of texture and intergranular strain

The micromechanics of plastic deformation behavior of a selective laser melt processed austenitic stainless steel were studied by investigating the evolutions of texture and intergranular strain using in situ high-energy synchrotron x-ray diffraction (sXRD). The effects of defect characteristics on tensile behavior were studied using three different samples: a near full-density sample with elliptical closed voids and two samples with lack-of-fusion (LOF) defects tensile loaded either perpendicular or parallel to their major axes. The evolutions of pole figures and inverse pole figures show that the full-density specimen develops a strong (111)/(200) fiber texture along the loading direction. For both LOF specimens, the evolution of texture is qualitatively similar to the full-density counterpart, but the development of the fiber texture was much slower, indicating a limited plasticity at a given macroscopic strain. The intergranular strain evolution in the full-density specimen is similar to that of a wrought 316L stainless steel. Conversely, a significantly different intergranular strain development was observed in a LOF specimen, where tensile strain development was observed in both the axial and transverse directions. Finally, the influence of defect type, density, and orientation on the local stress states in the steel matrix and the evolutions of intergranular strains is discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Science and Technology of High Performance Ferritic (HiperFer) Stainless Steels

Future, flexible thermal energy conversion systems require new, demand-optimized high-performance materials. The High performance Ferritic (HiperFer) stainless steels, under development at the Institute of Microstructure and Properties of Materials (IEK-2) at Forschungszentrum Jülich GmbH in Germany, provide a balanced combination of fatigue, creep and corrosion resistance at reasonable price. This paper outlines the scientific background of alloy performance development, which resulted in an age-hardening ferritic, stainless steel grade. Furthermore, technological properties are addressed and the potential concerning application is estimated by benchmarking versus conventional state of the art materials.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Data on Cu- and Ni-Si-Mn-rich solute clustering in a neutron irradiated austenitic stainless steel

The data presented in this article is supplementary to the research article “Phase instabilities in austenitic steels during particle bombardment at high and low dose rates” (Levine et al.). Needle-shaped samples were prepared with focused ion beam milling from a 304L stainless steel that was irradiated with fast neutrons (E 0.1 MeV) in the BOR-60 reactor at 318 °C to 47.5 dpa. Atom probe tomography (APT) experiments in voltage mode were then conducted on a Cameca LEAP 5000X HR. Atom position, range, and mass spectrum files after reconstruction with Cameca’s IVAS software are included. Cu- and Ni-Si-Mn-rich solute nanoclusters were identified and analyzed using the Open Source Characterization of APT Reconstructions (OSCAR) program. Python code for OSCAR, information on the program’s underlying algorithm, and sample output files are provided. A proximity histogram of a Ni-Si-Mn-rich cluster and a 1D density/solute concentration profile of a Cu-rich cluster are given to demonstrate OSCAR’s analytical functionalities. The provided APT dataset is valuable for benchmarking phase instabilities in neutron-irradiated austenitic stainless steels that occur at high doses. The OSCAR program can be reused to process other APT data sets where solute nanoclustering is of interest.

42 ENGINEERING↗
DOE OSTI2026

Process-driven roadmap for depositing super duplex stainless steel via wire Arc additive manufacturing

Here, this study systematically investigates the effects of shielding gas, bead spacing, weld mode, and travel speed on the phase balance, porosity, and hardness of wire arc additively manufactured (WAAM) super duplex stainless steel (ER2594). Robotic WAAM was employed to fabricate multilayer walls under systematically varied process conditions, followed by phase transformation simulations, X-ray computed tomography (XCT), electron backscatter diffraction (EBSD), and microhardness evaluation. Thermodynamic simulations predicted rapid cooling of AM process can suppress the potential formation of deleterious precipitates which was later validated via cross-sectional microstructure analyses of printed samples. XCT revealed porosity levels below 0.2% for all deposits, with reduced travel speed significantly lowering defect volume. Microstructural analyses revealed the evolution of various austenite precipitates, including grain boundary austenite (GBA), Widmanstätten austenite (WA), and intergranular austenite (IGA), sequentially upon cooling of the ferrite phase. Among all process parameters, weld transfer mode exhibited the strongest influence on phase balance; pulsed mode promoted higher ferrite retention (~ 36%) compared to RapidX mode. No consistent relationship between stabilized phase fraction and captured microhardness was observed. This work provides critical insights for optimizing WAAM parameters to control phase balance and mechanical performance, which is essential for producing high-integrity super duplex stainless-steel components for nuclear and marine applications.

Grain orientation↗
DOE OSTI2020

Laser powder bed fusion of Inconel 718 on 316 stainless steel

The joining of Inconel 718 and 316 stainless steel has notable industrial importance. However, traditional arc-welding has many issues. In particular, the formation of the detrimental Nb-rich Laves phase in the heat affected zone can promote crack initiation and propagation, which leads to poor mechanical properties. The small heat input and the rapid solidification of laser powder bed fusion (PBF) has the potential to suppress this problem. Despite the infancy of the multi-material PBF, it is of interest to investigate the relationship among the process parameter, the microstructure at the materials joining point, and the mechanical performance. In this study, we used high-speed x-ray imaging to in-situ monitor the printing of Inconel 718 tracks on a 316H SS substrate via laser powder bed fusion, followed by post-build characterization and testing with SEM, XRD and nanoindentation. We observed that a higher linear energy density resulted in a more diffused interface and a smaller compositional gradient, but as a trade-off, generated more keyhole pores and thermal cracks. Furthermore, we also showed that the built layer exhibited chemical inhomogeneity at two length scales: a tens-of-mu m-scale compositional vortex due to the melt flow, and a sub-mu m-scale Nb-rich dendritic structure due to the non-equilibrium solidification that led to the formation of the Laves phase. It was inferred that the chemical inhomogeneity may benefit the mechanical properties at the interface by providing more interlocking between the two materials and also by limiting the effect of the brittle Laves phase to potentially short range.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Long-Term Effects of Humidity on Stainless Steel Pitting in Sea Salt Exposures

Ground 304 stainless steel (SS) samples were exposed to sea salt particles at 35 °C and two relative humidity (RH) levels for durations ranging from 1 week to 2 years. For all exposure times, pit number density and total pit volume at 40% RH were observed to be considerably greater than those at 76% RH. Statistical analysis of distributions of pit populations for both RH conditions showed that pit number density and total pit volume increased rapidly at first but slowed as exposure time increased. Cross-hatched features were observed in the 40% RH pits while ellipsoidal, faceted pits were observed at 76% RH. Optical profilometry indicated that most pits were not hemispherical. X-ray tomography provided evidence of undercutting and fissures. Piecewise curve fitting modeled the 40% RH data closely, predicting that corrosion damage would eventually plateau. However, a similar treatment of the 76% RH data suggested that corrosion damage would continuously increase, which implied that the piecewise power-law fit was limited in its ability to model atmospheric corrosion generally. Based on these observations, the operative mechanisms determining long-term corrosion behavior were hypothesized to be different depending on the RH of exposure.

36 MATERIALS SCIENCE↗
NASA NTRS1973

A mechanical property and stress corrosion evaluation of 431 stainless steel alloy

The mechanical properties of type 431 stainless steel in two conditions: annealed bar and hardened and tempered bar are presented. Test specimens, manufactured from approximately 1.0 inch (2.54 cm) diameter bar stock, were tested at temperatures of 80 F (+26.7 C), 0 F (-17.8 C), -100 F (-73 C), and -200 F (-129 C). The test data indicated excellent tensile strength, notched/unnotched tensile ratio, ductility, shear, and impact properties at all testing temperatures. Results of the alternate immersion stress corrosion tests on stressed and unstressed longitudinal tensile specimens 0.1250 inch (0.3175 cm) diameter and transverse C-ring specimens, machined from 1.0 inch (2.54 cm) diameter bar stock, indicated that the material is not susceptible to stress corrosion cracking when tested in a 3.5 percent NaCl solution for 180 days.

Montano, J. W.↗