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At least 289 records · Page 16
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Manufacturability and performance response of developed Ni-based alloys for reactor environments

Under the Advanced Materials and Manufacturing Technologies program, two Ni-based alloys fabricated by laser powder bed fusion (LPBF) at ORNL and laser powder directed energy deposition (LP-DED) at INL have been evaluated: γ′-strengthened Haynes 282 and solution-strengthened Inconel 625. Printing defects were observed in the LPBF 282 alloy fabricated using a Renishaw AM250 machine, likely due to particle spattering during printing. For both the LPBF and LP-DED 282 alloys, annealing at 1,180°C for 1 h resulted in partial recrystallization and a bimodal grain distribution, while subsequent aging for 4 h at 800°C led to the formation of a high density of nano size γ′-strengthening precipitates. Creep testing performed at 750°C revealed lower creep life and ductility for the LPBF and LP-DED 282 compared with wrought 282. X-ray computed tomography combined with optical and scanning electron microscopy microstructural characterization revealed crack formation in the LPBF 282 alloy during creep testing, initiated either from printing defects or from creep cavitation at grain boundaries. Creep cavitation and cracking at grain boundaries were also observed for the LP-DED 282 alloy, and optimization of the printing strategies and post heat treatments will be needed to fabricate high performance 282 components for high temperature nuclear applications.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

Residual Strains in an Additively Processed Ni-based Superalloy Transpiration-Cooled Aerodynamic Leading Edge Structure using Neutron Diffraction

Selective Laser Melting (SLM) is a well-known additive manufacturing method based on a layer-by-layer building process that is capable of fabricating gas turbine Ni-based superalloy parts with complex and integrated cooling geometries that are typically not achievable using conventional casting methods. However, the impact of residual stress concentration on SLM component life is a concern. In this work, residual strains present at room temperature in an SLM Inconel 718 generic aerodynamic leading edge segment with transpiration cooling were investigated using neutron diffraction at Oak Ridge National Laboratory. This study reveals that areas of the part where complex cooling holes were printed exhibit residual tensile strains that can be detrimental to its integrity. The study paves the way for future studies of the design of cooling hole geometries and manufacturing parameters that achieve improved cooling while minimizing stress concentration effects.

Fouliard, Quentin↗
DOE OSTI2021

Development of Precipitation-Strengthened Al 0.8 NbTiVM (M = Co, Ni) Light-Weight Refractory High-Entropy Alloys

Single-phase solid-solution refractory high-entropy alloys (RHEAs) have been receiving significant attention due to their excellent mechanical properties and phase stability at elevated temperatures. Recently, many studies have been reported regarding the precipitation-enhanced alloy design strategy to further improve the mechanical properties of RHEAs at elevated temperatures. In this study, we attempted to develop precipitation-hardened light-weight RHEAs via addition of Ni or Co into Al 0.8 NbTiV HEA. The added elements were selected due to their smaller atomic radius and larger mixing enthalpy, which is known to stimulate the formation of precipitates. The addition of the Ni or Co leads to the formation of the sigma precipitates with homogeneous distribution. The formation and homogeneous distribution of sigma particles plays a critical role in improvement of yield strength. Furthermore, the Al 0.8 NbTiVM 0.2 (M = Co, Ni) HEAs show excellent specific yield strength compared to single-phase AlNbTiV and NbTiVZr RHEA alloys and conventional Ni-based superalloy (Inconel 718) at elevated temperatures.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Modeling the Impact of Grain Size on Corrosion Behavior of Ni-Based Alloys in Molten Chloride Salt via Cellular Automata

Molten chloride salts hold significant promise as both thermal transfer and storage media for next-generation concentrated solar power (CSP) systems. However, molten chlorides pose a considerable corrosion risk to structural materials, particularly Ni-based alloys. One approach to enhancing corrosion resistance is through the optimization of grain structure; however, it remains uncertain whether increasing or decreasing grain size enhances corrosion resistance. A cellular automata (CA) program was developed to evaluate the interplay between grain size and corrosion in Ni-based alloy. Our CA program tracks alloy composition, surface roughness, and thickness loss via a graphical user interface, displaying corrosion and diffusion status, and multiple user input cards for tuning the simulation. CA simulations of Inconel 625 indicate enhanced corrosion resistance with increased grain size, with passivating oxides offering limited protection. Additionally, the temporal evolution of alloy surface roughness demonstrates notable fluctuations, with abrupt increases attributed to corrosion along vertical grain boundaries and sudden decreases to grain detachment from the protective film.

Materials Science↗
DOE OSTI2021

A Scalable Solution Route to Porous Networks of Nanostructured Black Tungsten

This paper studied the feasibility of a new solution-processed method to manufacture black tungsten nanostructures by laser conversion of tungsten hexacarbonyl precursor on the Inconel 625 substrate under argon atmosphere at ambient pressure. The results show that sublimation of the precursor can be prevented if the decomposition temperature (>170 °C) is achieved using the laser heating method. Three different laser powers from 60–400 W were used to investigate the role of laser parameters on the conversion. It was found that lower laser power of 60 W resulted in a mixture of unconverted precursor and converted tungsten. Higher laser powers >200 W resulted in α-W (BCC) in one step without further heat treatment. Different oxygen concentrations from 0.5 ppm to 21 vol% were used in the laser canister to investigate the effect of oxygen concentration on the conversion. It was found that the hard vacuum (>10−4 torr) or hydrogen is not necessary to obtain α-W (BCC). The solar absorptance varied from 63–97%, depending on the amount of precursor deposited on the substrate and oxygen content in the laser canister. This solution-based laser conversion of tungsten precursor is a scalable method to manufacture tungsten coatings for high-temperature applications.

14 SOLAR ENERGY↗
DOE OSTI2023

High Temperature Ternary Chloride Molten Salt Pump

A ternary chloride (MgCl2-NaCl-KCl) molten salt pump has been developed to operate up to 720°C. The design is the result of a thermal, structural and material study of critical components. The vertical overhung pump incorporates first of a kind salt-wetted hydrodynamic bearings. Several bearing material pairings were tested which include: colmonoy grades, stellite grades, and a novel NiWC-based alloy (i.e. HybrimetTM NiWC3b) used as a High Velocity Oxygen Fuel (HVOF) coating. The coating withstands the corrosion effects of the molten salt, and is also used to protect a 316L stainless steel pump reservoir. The pump bowl assembly components are made of Inconel 625. A Nitrogen flushed carbon ring seal is used to keep salt vapors from interacting with external ambient air. Preliminary testing shows a promising pump design for use in the Concentrating Solar Power Gen 3 systems and sets the ground for further development of the HybrimetTM NiWC3b as a competitive alternative to available superalloys.

Handy-Cardenas, Lewis (ORCID:0009000744006972)↗
DOE OSTI2026

Prototype Modeling for a Light-Trapping Planar-Cavity Enclosed Particle Solar Receiver

Concentrating solar thermal (CST) systems present a promising avenue for affordable and reliable energy production. Solar receivers are key components that determine the efficiency and longevity of these systems. Particle-based solar receivers have emerged as a compelling alternative to traditional technologies, offering several advantages that address limitations in current CST systems. This is especially true as next-generation CST technologies target applications including electricity generation, thermochemical processes, and industrial process heat, many of which necessitate higher operating temperatures than current commercial molten salt systems. Molten-salt thermal energy storage (TES) systems, commonly used in CSP, face challenges related to freezing and corrosion. Particle-based TES systems, in contrast, do not experience these issues, as particles are stable at high temperatures, exceeding 1000 degrees Celsius. This capability allows for a wider range of applications, including those requiring higher temperatures for industrial processes and efficient electricity generation. A novel innovation in particle-based solar receiver technology is the light-trapping planar cavity receiver (LTPCR) configuration developed by NREL. The LTPCR design consists of small cavity-like structures using opaque planar surfaces, enabling efficient capture and absorption of solar energy. A high incident flux concentration at the cavity aperture is absorbed on the receiver walls, and subsequently transferred to particles on the inside of cavities. The particles flow through the system, forming a fluidized bed inside of the receiver panels, effectively capturing the absorbed solar heat. Air is used as a fluidizing medium in this process to enhance particle heat transfer and mixing. The effectiveness of this design lies in its ability to manage solar flux conditions and ensure high solar-to-thermal receiver efficiency. A 100-kW prototype is currently being tested at the King Saud University in Saudi Arabia to assess the receiver performance. A range of modeling analyses for the optical, thermal, and mechanical effects were conducted to assess the performance of the receiver under on-sun conditions. The solar flux resulting from the KSU heliostat field was modeled using NREL SolTrace software and produced up to 600 kW/m2 at the receiver aperture. The solar flux absorbed on the receiver walls was then used within a computational fluid dynamics (CFD) model to predict wall temperature distributions along with radiation and convection loss. A two-phase CFD model was developed for the fluidized bed of silica sand inside the receiver panels to predict local wall-to-particle heat transfer coefficients, particle temperature distributions, and outlet temperature of the particles. We have also conducted analyses to understand the thermomechanical behavior of these innovative enclosed light-trapping solar receivers optimized for particle heating. We used finite element analysis (FEA) to predict the receiver's performance using temperature distributions obtained from CFD and based on the resulting stress profiles, evaluated creep-fatigue damage with a goal of achieving a 30-year service life. Analysis showed a significant impact of the particle-to-wall heat transfer coefficients (HTCs) on receiver performance, with higher HTCs resulting in reduced stress and increased lifespan. For instance, when using Inconel 740H, increasing the HTC from 800 W/m2 K to 1400 W/m2 K increased the creep life from 4,000 hours to over 100,000 hours. This highlights the importance of understanding and optimizing heat transfer in the design of high-efficiency receivers.

14 SOLAR ENERGY↗
DOE OSTI2022

Corrosion evaluation of metal foams in eutectic molten salts for high temperature latent heat energy storage application

High-temperature Thermal Energy Storage (TES) has drawn great attention as a technology that can increase the role and profitability of micro nuclear reactors in the decentralized clean energy market. Various research needs have been proposed by Idaho National Laboratory (INL) in "the Integrated Energy Systems: 2020 Roadmap" with the goal of utilizing the high temperature of 550 degrees or more generated in the 4th generation reactor to industrial purposes from the standpoint of integrated energy systems [1]. With the recent development of the 4th generation nuclear power plant, including micro nuclear reactor, there is a great deal of interest in researching how to efficiently couple a heat source to an industrial process through thermal processing. Texas A&M University (TAMU) and INL are currently collaborating to develop a novel latent heat storage design called HITB (Heat pipe-Integrated Thermal Battery). As part of the small-scale experimental demonstration research for HITB, a study for storage medium selection was conducted at TAMU. Eutectic salts have attracted interest as high-temperature heat storage medium for HITB. Especially, chloride molten salts and fluoride molten salts are considered promising candidates due to their high melting temperature, thermal stability, and high latent heat of fusion. Since eutectic salts have poor thermal conductivity in general, it is critical to distribute materials with high thermal conductivity evenly to facilitate the charging and discharging of heat. In this study, metal foam was considered in the HITB system to overcome the poor heat transfer characteristics of eutectic salts. In order to improve heat transfer, it is necessary to study materials with high thermal conductivity, corrosion resistant to molten salts, such as fins, extended surfaces, particles, microcapsulation, or foam structure. Porous structure of copper or aluminum can increase heat transfer area, form a thermal transfer network, and increase the effective thermal conductivity of thermal storage medium [2]. Since the melting temperature is required to be at least 450? in the current HITB design, various eutectic salts are being considered. FLiNaK and FLiBe, which are famous for fluoride salts, are good candidates, but due to the sharp rise in the price of LiF recently, they are excluded for economic reasons to be applied to large-capacity thermal energy storage. On the other hand, chloride salts are very cheap and easy to obtain, have a high melting temperature, and have a high latent heat of fusion, so they are recently in the spotlight as a phase change material. However, because of the hygroscopic nature of chloride salts, HCl gas due to impurity is easy to be released and is particularly vulnerable to corrosion. Chloride eutectic salts have been tested and suggested for metal alloys that are particularly resistant to corrosion, such as SS304, SS316, Hastelloy, Inconel 625, Incoloy 800H, which has low thermal conductivity, and is very expensive [3-6]. Porous materials with high thermal conductivity such as copper and aluminum have been tested for stability in fluids such as paraffin or water as metal foam or metal fin structures, but high temperature corrosion tests were not performed on various eutectic salts yet. Therefore, this study investigated the high temperature corrosion characteristics of metal alloys, such as C10100 foam, C10100 plate, 6101 alloy foam, and SS316 plate, while immersed in the candidate eutectic salts. A total of 20 tests for SS316 coupons and 10 tests for C10100 coupons were performed to ensure the repeatability of the present measurements. Since it is difficult to completely remove the salt inside metal foam due to the complex inner structure of the metal foam, only the surface condition was observed with a microscopy and scanning electron microscopy (SEM) image, except for measuring the corrosion rate and average mass loss.

25 ENERGY STORAGE↗
DOE OSTI2022

Application of the Continuum Damage Mechanics Wilshire-Cano-Stewart (WCS) Model

In this study, the applications of the continuum damage mechanics-based Wilshire-Cano-Stewart (WCS) model are explored to predict rupture time, minimum-creep-strain-rate (MCSR), damage, damage evolution, and creep deformation. Increase knowledge in manufacturing methods has pushed the limit of material science and the development of new materials. Conventional testing is required to qualify materials against creep which according to the ASME B&PV III code, 10,000+ hours of experiments are necessary for each heat before materials are put into service. This process is costly and not feasible for new materials. As an alternative, models have been employed to predict creep behaviors and reduce the amount of time necessary for material qualification. Many models have been developed to predict distinct creep behaviors and the question of which model is best remains. Amongst current models, the WCS model has emerge with the ability to predict multiple behaviors using an explicit analytical approach with the ability to predict long-term creep. In this study the novel continuum damage mechanics WCS is employed in multiple applications. The goals of the study are (a) to discuss and determine the framework of the WCS model and validated it mathematically and using parametric simulations, (b) applied the model to accelerated creep data to show the capabilities of the model with non-conventional data, and (c) applied a novel numerical method, the datum temperature method (DTM) to show the model extrapolations and interpolations capabilities with limited and reduce data sets. To accomplish these goals, data is gathered for alloy P91 and Inconel 718 to develop and post-audit validate the model. The benefits of using the WCS model is that it provides an explicit stress and temperature dependency ideal for extrapolations, the coupled equations are suitable for finite element analysis (FEA) implementation, and it follows an explicit calibration approach. The model also proves that it can be applied to accelerated testing data and using the DTM.

Cano, Jaime A↗
DOE OSTI2023

High Temperature Ternary Chloride Molten Salt Pump

This work investigates the design criteria considering thermal, structural, and material selection of a ternary chloride (MgCl2-NaCl-KCl) molten salt pump that is capable of running at temperatures above 720 °C. In this work, preliminary testing of salt-wetted hydrodynamic bearings was done to investigate different material pairings including Colmonoy grades, Stellite grades, and a novel Nickel Tungsten Carbide alloy (HybrimetTM NiWC3b) used as a High Velocity Oxygen Fuel (HVOF) coating. The coating has shown to withstand the corrosive nature of the molten salt. The pump wetted components are made of Inconel 625 and features a carbon ring seal (CIRPAC Seal) flooded with a N2 gas flow on the overhead to keep salt vapors from interacting with the external ambient air. A comprehensive pump test program has been completed. Over 90 hours run time pumping hot chloride salts at temperatures up to 720 °C in which enough data was captured to produce performance curves at 3 different operating speeds. This research showcases a promising design for use in the Concentrated Solar Power (CSP) Gen 3 liquid-pathway and sets the ground for further development and use of the HybrimetTM NiWC3b as a competitive alternative to available superalloys.

14 SOLAR ENERGY↗
DOE OSTI2023

Design and Fabrication of a Temperature-Controlled Fueled Molten Salt Capsule Irradiation Experiment

Idaho National Laboratory (INL) is developing a Molten salt Research Temperature-controlled Irradiation (MRTI) experimental capsule for the Neutron Radiography (NRAD) reactor. The experiment is envisaged to be versatile and able to host a variety of salt-wall material combinations. The first test is designed to contain actinide-bearing chloride salt, which previously has not been subjected to a neutron field. The main objectives of the experiment are to produce irradiated salt samples for Post Irradiation Examination (PIE), to evaluate salt behavior under irradiation, and to test in-situ sensors/instrumentation. The final design for the experiment completed in 2022, and fabrication of the experiment is underway. The salt is double encapsulated providing insulation and redundancy in the case of leakage. A gas-gap between the inner capsule and the outer container enables tuning of thermal conduction to the NRAD coolant by altering its thickness and its gas-mixture. An inert gas mixture ratio in the gas-gap ensures the configurations reached a targeted average salt temperature of 600oC, while avoiding salt freezing or exceeding material limits. A resistive heater placed within a thermowell and controls the temperature of the experiment (both when the reactor is on or off). The selected configurations can contain over 10 cm3 of fuel-bearing chloride salt, which is sufficient for the purposes of the post-irradiation examination (PIE) and provides sufficient volume for two submerged thermocouple probes to monitor salt temperature. The capsule wall material is Inconel 625, and weld qualifications for the assembly have been developed. A glove-box laser weld technique was refined as part of this process to ensure a leak-tight assembly for the salt-bearing assembly and reduce the risks of impurities permeating into the salt. This work was supported through the INL Laboratory Directed Research & Development (LDRD) Program under DOE Idaho Operations Office Contract DE-AC07-05ID14517.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

ENYGF 2023 - Design of Temperature-controlled Fuel-salt Irradiation Experiment

Idaho National Laboratory (INL) is developing a Molten salt Research Temperature-controlled Irradiation (MRTI) experimental capsule for the Neutron Radiography (NRAD) reactor. The experiment is envisaged to be versatile and able to host a variety of salt-wall material combinations. The first test is designed to contain actinide-bearing chloride salt, which previously has not been subjected to a neutron field. The main objectives of the experiment are to produce irradiated salt samples for Post Irradiation Examination (PIE), to evaluate salt behavior under irradiation, and to test in-situ sensors/instrumentation. The final design for the experiment completed in 2022, and fabrication of the experiment is underway. The salt is double encapsulated providing insulation and redundancy in the case of leakage. A gas-gap between the inner capsule and the outer container enables tuning of thermal conduction to the NRAD coolant by altering its thickness and its gas-mixture. An inert gas mixture ratio in the gas-gap ensures the configurations reached a targeted average salt temperature of 600oC, while avoiding salt freezing or exceeding material limits. A resistive heater placed within a thermowell and controls the temperature of the experiment (both when the reactor is on or off). The selected configurations can contain over 10 cm3 of fuel-bearing chloride salt, which is sufficient for the purposes of the post-irradiation examination (PIE) and provides sufficient volume for two submerged thermocouple probes to monitor salt temperature. The capsule wall material is Inconel 625, and weld qualifications for the assembly have been developed. A glove-box laser weld technique was refined as part of this process to ensure a leak-tight assembly for the salt-bearing assembly and reduce the risks of impurities permeating into the salt. This work was supported through the INL Laboratory Directed Research & Development (LDRD) Program under DOE Idaho Operations Office Contract DE-AC07-05ID14517.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Directed energy deposition of radially functionally graded nickel based superalloys IN625 and IN738: Microstructure and mechanical properties

This study investigates the microstructure and mechanical properties of radially functionally graded (RFG) materials fabricated from nickel-based superalloys IN625 and IN738 using directed energy deposition (DED). RFG cylindrical deposits with radial gradients of IN625-IN738 and IN738-IN625 were successfully fabricated and confirmed to be crack-free through tailored composition grading, scan strategy and process parameters that minimized thermal gradients and solidification velocities. Microstructural analysis revealed distinct variations across the gradient, characterized by differences in dendrite arm spacing, microsegregation, and the formation of distinct γ' precipitates and carbide/boride phases (MC, M 6 C, M 2 C, and MB 2 ) in as-deposited (AD) conditions, which evolved into M 23 C 6 and M 2 B upon subsequent heat treatment (HT). EBSD showed predominant columnar grains with a [100] texture, while microhardness profiles demonstrated consistent variation across the gradients. Mechanical testing highlighted the synergy of the graded structure, combining IN738's strength with IN625's ductility, resulting in enhanced properties such as a yield strength of 1131 MPa, ultimate tensile strength of 1382 MPa, and elongation of 12 % for HT IN625-IN738 grading. Numerical simulations employing CALPHAD thermodynamic calculations and finite element thermal modeling are used to establish phase evolution and microstructural feature correlation with thermal profiles, aiding in the optimization of process-structure-property relationship.

Additive manufacturing↗
DOE OSTI2022

Evaluation of HCF strength of Alloy 625 with non-optimum additive manufacturing process parameters

An extensive experimental program was undertaken to generate the process-structure-HCF property data for additive-manufactured Alloy 625. Round tensile and flat dog-bone HCF specimens were fabricated using a laser powder bed fusion process. Several builds were fabricated with different processing parameters. The fatigue strengths were determined using a step-test method and fracture surfaces were characterized to identify the critical microstructure feature associated with the formation of the fatigue crack. Finally, a fracture mechanics-based methodology using fatigue crack growth data measured on a wrought alloy is shown to provide conservative estimates of the HCF lives for the additive-manufactured alloy.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Characterization of γ′/γ″ compact and sandwich type precipitates during long-term high-temperature exposure in Ni-based superalloys

Here, the formation of γ′/γ″ co-precipitates is investigated in Ni-based superalloys with a varying Ti/Al ratio and Ta content and their stability is studied using long-term high-temperature exposure. Transmission electron microscopy and atom probe tomography analyses demonstrate that both higher Ti/Al ratios and increased Ta promote γ″ phase formation, leading to sandwich and compact structures. The compact co-precipitation significantly reduces γ′ precipitate coarsening during 10,000 h exposure at 700°C by restricting elemental diffusion, particularly of aluminum, from the γ matrix to the γ′ phase. For the alloy without a compact structure, and only γʹ precipitates, at the beginning of the exposure, the coarsening rate over 10,000 h was 3.5 times faster than for the alloy with compact γʹ/γʺ precipitates. Evidence of destabilization of the compact morphology was found to occur between 5,000 and 10,000 h exposure and originated from the extensive formation and growth of δ platelets that extended throughout the grains. Thus, the outer layer of the compact, which consists of γʺ, was subjected to the γ″ to δ phase transformation.

gamma double prime↗
DOE OSTI2020

As-Run Neutronics Evaluation for the CSM-10584 Experiment in the ATR

This engineering calculations and analysis report (ECAR) documents the results of the Advanced Test Reactor (ATR) detailed Monte Carlo N-Particle (MCNP) code full-core model as-run physics analysis performed to support the Colorado School of Mines (CSM) experiment in the B-5 position.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2020

As-Run Thermal Analysis for the CSM-10584 Experiment

The purpose of this document is to present the as-run specimen temperatures for the CSM-10584 experiment irradiated in position B-5 of the Advanced Test Reactor (ATR) for Cycles 164A and 164B.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2021

An Accelerated Creep Testing (ACT) Program for Advanced Creep Resistant Alloys for High Temperature Fossil Energy (FE) Applications (Final Report)

The research objective of this study is to develop an accelerated creep testing (ACT) program for advanced creep resistant alloys for high temperature FE applications. This research produced a new ACT for metallic materials based on Time-Temperature-Stress Superposition (TTSSP). In TTSSP, there exists a fundamental relationship between creep resistance, time, temperature, and stress that can be manipulated to reduce test durations. In our study, the stepped isostress method was employed where step increases of load during creep testing accelerated the time-to-rupture. Well-posed constitutive models including sin-hyperbolic and Wilshire-Cano-Stewart where calibrated using the SSM data and employed to predict the conventional creep response of the material. In our best experiments, <100-hour tests on lnconel 718 at 750 deg C produced over a 64x acceleration of data when compared to conventional data from Japan's National Institute of Materials Science. The ACTs enable the rapid screening of candidate materials, where a small test matrix of short duration tests can be employed to determine the creep resistance (minimum-creep-strain-rate, stress-rupture, and creep deformation) of a material across decades.

20 FOSSIL-FUELED POWER PLANTS↗