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DOE OSTI2024

Atomic Diffusivities of Yttrium, Titanium and Oxygen Calculated by Ab Initio Molecular Dynamics in Molten 316L Oxide-Dispersion-Strengthened Steel Fabricated via Additive Manufacturing

Oxide-dispersion-strengthened (ODS) steels have long been viewed as a prime solution for harsh environments. However, conventional manufacturing of ODS steels limits the final product geometry, is difficult to scale up to large components, and is expensive due to multiple highly involved, solid-state processing steps required. Additive manufacturing (AM) can directly incorporate dispersion elements (e.g., Y, Ti and O) during component fabrication, thus bypassing the need for an ODS steel supply chain, the scale-up challenges of powder processing routes, the buoyancy challenges associated with casting ODS steels, and the joining issues for net-shape component fabrication. In the AM process, the diffusion of the dispersion elements in the molten steel plays a key role in the precipitation of the oxide particles, thereby influencing the microstructure, thermal stability and high-temperature mechanical properties of the resulting ODS steels. In this work, the atomic diffusivities of Y, Ti, and O in molten 316L stainless steel (SS) as functions of temperature are determined by ab initio molecular dynamics simulations. The latest Vienna Ab initio Simulation Package (VASP) package that incorporates an on-the-fly machine learning force field for accelerated computation is used. At a constant temperature, the time-dependent coordinates of the target atoms in the molten 316L SS were analyzed in the form of mean square displacement in order to obtain diffusivity. The values of the diffusivity at multiple temperatures are then fitted to the Arrhenius form to determine the activation energy and the pre-exponential factor. Given the challenges in experimental measurement of atomic diffusivity at such high temperatures and correspondingly the lack of experimental data, this study provides important physical parameters for future modeling of the oxide precipitation kinetics during AM process.

Chemistry↗

DOE OSTI2024

Multiscale Modeling of Nanoparticle Precipitation in Oxide Dispersion-Strengthened Steels Produced by Laser Powder Bed Fusion

Laser Powder Bed Fusion (LPBF) enables the efficient production of near-net-shape oxide dispersion-strengthened (ODS) alloys, which possess superior mechanical properties due to oxide nanoparticles (e.g., yttrium oxide, Y-O, and yttrium-titanium oxide, Y-Ti-O) embedded in the alloy matrix. To better understand the precipitation mechanisms of the oxide nanoparticles and predict their size distribution under LPBF conditions, we developed an innovative physics-based multiscale modeling strategy that incorporates multiple computational approaches. These include a finite volume method model (Flow3D) to analyze the temperature field and cooling rate of the melt pool during the LPBF process, a density functional theory model to calculate the binding energy of Y-O particles and the temperature-dependent diffusivities of Y and O in molten 316L stainless steel (SS), and a cluster dynamics model to evaluate the kinetic evolution and size distribution of Y-O nanoparticles in as-fabricated 316L SS ODS alloys. The model-predicted particle sizes exhibit good agreement with experimental measurements across various LPBF process parameters, i.e., laser power (110–220 W) and scanning speed (150–900 mm/s), demonstrating the reliability and predictive power of the modeling approach. The multiscale approach can be used to guide the future design of experimental process parameters to control oxide nanoparticle characteristics in LPBF-manufactured ODS alloys. Additionally, our approach introduces a novel strategy for understanding and modeling the thermodynamics and kinetics of precipitation in high-temperature systems, particularly molten alloys.

Wang, Zhengming (ORCID:0000000241627112)↗

DOE OSTI2022

Nanoindentation Investigation of Chloride-Induced Stress Corrosion Crack Propagation in an Austenitic Stainless Steel Weld

Transgranular chloride-induced stress corrosion cracking (TGCISCC) is a mounting concern for the safety and longevity of arc welds on austenitic stainless steel (AuSS) nuclear waste storage canisters. Recent studies have shown the key role of crystallography in the susceptibility and propagation of TGCISCC in SS weldments. Given that crystallography underlies mechanical heterogeneities, the mechanical-crystallographic relationship during TGCISCC growth must be understood. In this study, welded SS 304L coupons are loaded in four-point bend fixtures and then boiled in magnesium chloride to initiate TGCISCC. Nanoindentation mapping is paired with scanning electron microscopy (SEM) electron backscatter diffraction (EBSD) to understand the correlation between grain orientation, grain boundaries, and hardening from TGCISCC propagation. The nanoindentation hardness of individual grains is found to not be a controlling factor for TGCISCC propagation. However, intragranular hardness is generally highest immediately around the crack due to localized strain hardening at the crack tip. This work shows that nanoindentation techniques can be useful in understanding CISCC behaviors when paired with electron microscopy.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Study of Mechanical Properties, Microstructure, and Residual Stresses of AISI 304/304L Stainless Steel Submerged Arc Weld for Spent Fuel Dry Storage Systems

The confinement boundaries of spent nuclear fuel (SNF) canisters are typically fusion welded. Welded microstructures, strain hardening, and residual stresses combined with a chemically aggressive, chloride-rich environment led to concerns that the welded canister may be susceptible to chloride-induced stress corrosion cracking (CISCC). A comprehensive understanding of the modification of stainless steel (SS) metallurgical and mechanical properties by fusion welding could accelerate the predictive analysis of CISCC susceptibility. This paper describes a submerged arc welding (SAW) procedure that was developed and qualified on 12.7 mm (0.5 in.) thick AISI 304/304L SS to produce joints in a way similar to actual SNF canister manufacturing. This procedure has the potential to reduce the production cost and weld CISCC susceptibility by using fewer welding passes and lower heat input than current industrial applications. Global and local mechanical behaviors and properties, as well as residual stress distributions on the welded joint, were studied. The results indicate that hardness values in the fusion zone (FZ) and heat-affected zone (HAZ) are slightly higher than that of the base metal. Strain localization was presented in the HAZ before the tensile stress reached its maximum value, and then it shifted to the FZ. The specimen finally broke in the FZ. High tensile residual stresses exhibited in the FZ and the nearby HAZ suggest the highest CISCC-susceptible spots. The maximum tensile residual stresses were along the welding direction, indicating that if cracks occur, they would be perpendicular to the welding direction. This study involved developing and qualifying a SAW procedure for SNF canister production. The new procedure yielded cost savings (SAW working efficiency increased by about 80%), improved mechanical properties, and presented moderate residual stresses. Analysis revealed that the welded joint’s low-stress and high-stress damage assessments may be affected by shifts in the strain localization spot under loading.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2024

Composite Ionogel Electrodes for Polymeric Solid-State Li-Ion Batteries

Realizing rechargeable cells with practical energy and power density requires electrodes with high active material loading, a remaining challenge for solid-state batteries. Here, we present a new strategy based on ionogel-derived solid-state electrolytes (SSEs) to form composite electrodes that enable high active material loading (>10 mg/cm 2 , ~9 mA/cm 2 at 1C) in a scalable approach for fabricating Li-ion cells. By tuning the precursor and active materials composition incorporated into the composite lithium titanate electrodes, we achieve near-theoretical capacity utilization at C/5 rates and cells capable of stable cycling at 5.85 mA/cm 2 (11.70 A/g) with over 99% average Coulombic efficiency at room temperature. Finally, we demonstrate a complete polymeric solid-state cell with a composite anode and a composite lithium iron phosphate cathode with ionogel SSEs, which is capable of stable cycling at a 1C rate.

25 ENERGY STORAGE↗

DOE OSTI2021

A Radial-velocity Search for Binary RR Lyrae Variables

We report 272 radial velocities for 19 RR Lyrae variables. For most of the stars we have radial velocities for the complete pulsation cycle. These data are used to determine robust center-of-mass radial velocities that have been compared to values from the literature in a search for evidence of binary systems. Center-of-mass velocities were determined for each star using Fourier Series and template fits to the radial velocities. Our center-of-mass velocities have uncertainties from ±0.16 km s{sup −1} to ±2.5 km s{sup −1}, with a mean uncertainty of ±0.92 km s{sup −1}. We combined our center-of-mass velocities with values from the literature to look for deviations from the mean center-of-mass velocity of each star. Fifteen RR Lyrae show no evidence of binary motion (BK And, CI And, Z CVn, DM Cyg, BK Dra, RR Gem, XX Hya, SZ Leo, BX Leo, TT Lyn, CN Lyr, TU Per, U Tri, RV UMa, and AV Vir). In most cases this conclusion is reached due to the sporadic sampling of the center-of-mass velocities over time. Three RR Lyrae show suspicious variation in the center-of-mass velocities that may indicate binary motion but do not prove it (SS Leo, ST Leo, and AO Peg). TU UMa was observed by us near a predicted periastron passage (at 0.14 in orbital phase) but the absence of additional center-of-mass velocities near periastron makes the binary detection, based on radial velocities alone, uncertain. Two stars in our sample show Hγ emission in phases 0.9–1.0: SS Leo and TU UMa.

47 OTHER INSTRUMENTATION↗

DOE OSTI2023

Sensitization of 316L Stainless Steel made by Laser Powder Bed Fusion Additive Manufacturing

Additively manufactured (AM) 316L stainless steel (SS) manufactured by laser powder bed fusion (L-PBF) and wrought 316L SS were subjected to sensitization heat treatments at 700°C up to 100 h. Using two evaluation methods, double-loop electrochemical potentiokinetic reactivation (DL-EPR) and ditching tests, degree of sensitization (DOS) and intergranular corrosion (IGC) susceptibility was evaluated. It was found that the wrought samples showed slightly lower IGC susceptibility compared to their AM counterpart. DOS and IGC attacks increased with sensitization time for all samples. Dislocation cellular structures were found to have little to no impact on DOS and IGC for the AM samples. Sensitized at 100 h, the AM sample showed significant Cr depletion along high-angle grain boundaries (12.35 wt% on average) and exhibited Cr carbide precipitation. Mo-rich particles along grain boundaries were also observed. The DL-EPR test attacks the surface oxide film and grain boundaries while the ditching test attacks the melt pool boundaries and grain boundaries (IGC and pitting). Changes to the DL-EPR and ditching standards for AM application have been proposed in this work.

316L stainless steel↗

DOE OSTI2021

The importance of Aitken mode aerosol particles for cloud sustenance in the summertime high Arctic – a simulation study supported by observational data

The potential importance of Aitken mode particles (diameters ~ 25–80 nm) for stratiform mixed-phase clouds in the summertime high Arctic (>80° N) has been investigated using two large-eddy simulation models. We find that, in both models, Aitken mode particles significantly affect the simulated microphysical and radiative properties of the cloud and can help sustain the cloud when accumulation mode concentrations are low (< 10–20 cm –3 ), even when the particles have low hygroscopicity (hygroscopicity parameter – κ=0.1). However, the influence of the Aitken mode decreases if the overall liquid water content of the cloud is low, either due to a higher ice fraction or due to low radiative cooling rates. An analysis of the simulated supersaturation (ss) statistics shows that the ss frequently reaches 0.5 % and sometimes even exceeds 1 %, which confirms that Aitken mode particles can be activated. The modelling results are in qualitative agreement with observations of the Hoppel minimum obtained from four different expeditions in the high Arctic. Our findings highlight the importance of better understanding Aitken mode particle formation, chemical properties and emissions, particularly in clean environments such as the high Arctic.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

Long-range transported continental aerosol in the eastern North Atlantic: three multiday event regimes influence cloud condensation nuclei

Abstract. The eastern North Atlantic (ENA) is a region dominated by pristine marine environment and subtropical marine boundary layer clouds. Under unperturbed atmospheric conditions, the regional aerosol regime in the ENA varies seasonally due to different seasonal surface-ocean biogenic emissions, removal processes, and meteorological regimes. However, during periods when the marine boundary layer aerosol in the ENA is impacted by particles transported from continental sources, aerosol properties within the marine boundary layer change significantly, affecting the concentration of cloud condensation nuclei (CCN). Here, we investigate the impact of long-range transported continental aerosol on the regional aerosol regime in the ENA using data collected at the U.S. Department of Energy's (DOE) Atmospheric Radiation Measurement (ARM) user facility on Graciosa Island in 2017 during the Aerosol and Cloud Experiments in the Eastern North Atlantic (ACE-ENA) campaign. We develop an algorithm that integrates number concentrations of particles with optical particle dry diameter (Dp) between 100 and 1000 nm, single scattering albedo, and black carbon concentration to identify multiday events (with duration >24 consecutive hours) of long-range continental aerosol transport in the ENA. In 2017, we detected nine multiday events of long-range transported particles that correspond to ∼ 7.5 % of the year. For each event, we perform HYSPLIT 10 d backward trajectories analysis, and we evaluate CALIPSO aerosol products to assess, respectively, the origins and compositions of aerosol particles arriving at the ENA site. Subsequently, we group the events into three categories, (1) mixture of dust and marine aerosols, (2) mixture of marine and polluted continental aerosols from industrialized areas, and (3) biomass burning aerosol from North America and Canada, and we evaluate their influence on aerosol population and cloud condensation nuclei in terms of potential activation fraction and concentrations at supersaturation of 0.1 % and 0.2 %. The arrival of plumes dominated by the mixture of dust and marine aerosol in the ENA in the winter caused significant increases in baseline Ntot. Simultaneously, the baseline particle size modes and CCN potential activation fraction remained almost unvaried, while cloud condensation nuclei concentrations increased proportionally to Ntot. Events dominated by a mixture of marine and polluted continental aerosols in spring, fall, and winter led to a statistically significant increase in baseline Ntot, a shift towards larger particular sizes, a higher CCN potential activation fractions, and cloud condensation nuclei concentrations of >170 % and up to 240 % higher than during baseline regime. Finally, the transported aerosol plumes characterized by elevated concentration of biomass burning aerosol from continental wildfires detected in the summertime did not statistically contribute to increase baseline aerosol particle concentrations in the ENA. However, particle diameters were larger than under baseline conditions, and CCN potential activation fractions were >75 % higher. Consequentially, cloud concentration nuclei concentrations increased by ∼ 115 % during the period affected by the biomass burning events. Our results suggest that, through the year, multiday events of long-range continental aerosol transport periodically affect the ENA and represent a significant source of CCN in the marine boundary layer. Based on our analysis, in 2017, the multiday aerosol plume transport dominated by a mixture of dust and marine aerosol, a mixture of marine and polluted continental aerosols, and biomass burning aerosols caused increases in the NCCN baseline regime of, respectively, 6.6 %, 8 %, and 7.4 % at SS 0.1 % (and, respectively, 6.5 %, 8.2 %, and 7.3 % at SS 0.2 %) in the ENA.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2021

Steep slope transistors with threshold switching devices

A steep-slope (SS) field effect transistor (FET) including a FET having a source region and a drain region, and a threshold switching device in direct contact with the source region or the drain region of the FET. Fabricating the steep-slope (SS) field effect transistor (FET) includes fabricating an AlGaN/GaN metal-insulator-semiconductor high electron mobility transistor (MIS-HEMT) having a source region and a drain region, depositing a first electrode layer directly on the source region or the drain region, depositing a threshold switching layer directly on the first electrode layer, and depositing a second electrode layer directly on the threshold switching layer.

Huang, Xuanqi↗

DOE OSTI2022

Friction Stir Welding – an Advanced Approach to Repair Nuclear Power Plant Components

Solid phase joining technique friction stir welding (FSW) has been shown to mitigate helium-related issues in fusion welding of irradiated steels. Here, we present detailed characterization results of the first friction stir weld of an irradiated 304L stainless steel (SS) coupon contained 5.2 atomic parts per million (appm) helium. Scanning electron microscopy (SEM) was used to characterize a cross section specimen removed from the friction stir weld. No macro helium induced crack was observed at the analyzed cross-section, and only 1 – 1.5 µm size pores were found in the stir zone (SZ) and the thermal-mechanical affected zone (TMAZ). Moreover, some minor helium aggregations (Maximum ~20 µm in length) appeared along grain boundaries inside the TMAZ. Thereafter, miniature tensile specimens were extracted from the SZ, TMAZ and heat affected zone (HAZ), and base metal (BM) and tested. All welded specimens showed high total elongations (> 60%) and strengths (> 75% BM strengths). Overall, the weld made by FSW showed much better results comparing with traditional fusion welding on irradiated SS.

Tang, Wei↗

DOE OSTI2020

Challenges and Solutions in Operation and Lay-Up of the Modular Caustic- Side Solvent Extraction Unit - 20078

The Modular Caustic-Side Solvent Extraction (CSSX) Unit (MCU) was designed and constructed to provide interim salt waste processing so that the Liquid Waste Disposition Program (LWDP) could continue waste removal and tank closure until start-up of the Salt Waste Processing Facility (SWPF). MCU processes Clarified Salt Solution (CSS), or salt solution (SS) that has undergone actinide removal/filtration, to produce two waste streams: the cesium laden Strip Effluent (SE), which is incorporated into glass at the Defense Waste Processing Facility (DWPF), and the cesium depleted Decontaminated SS (DSS), which is incorporated into grout at the Saltstone Production Facility (SPF). MCU completed start-up in 2008 with an initial operating life of 3 years and design life of 5 years. Prior to reaching the end of the design life, multiple critical components were upgraded and/or replaced to mitigate risks associated with any delays in SWPF start-up. During the remainder of operation (until June 2019), MCU was challenged to maximize processing with minimal additional modifications to repair/improve aging infrastructure, while maintaining low levels of risk to workers and the environment. Notable challenges during the extended operating life of the facility involved both mechanical and operational issues. Two of the most significant issues were the increased frequency of Process Vessel Ventilation (PVV) High Efficiency Particulate Air (HEPA) filter change-outs and the biofouling of the SE coalescer (SEC). The major impacts of both issues were that replacement of these components 1) resulted in high exposure to workers, and 2) required substantial downtime, thus hindering achievement of processing goals. PVV HEPA filter replacements are required based on dose rate and differential pressure (dP) limits. After introducing a higher-curie feed to MCU, the operating time between change outs was reduced by approximately half. SEC replacements are required based on dP limits. After restarting from an extended outage, the operating life of the SEC was significantly reduced by more than half due to biofouling. As a result of extensive troubleshooting and process improvements, the facility was able to recover performance and extend the operating life of the PVV HEPA filters and the SEC media. Through troubleshooting both of these issues, the facility was also able to learn from prior experience and adapt in order to minimize down time and maintain throughput. Although the facility took advantage of short periods of downtime to perform nonintrusive troubleshooting and minor corrective/preventative maintenance activities, longer outages were periodically required for corrective maintenance involving process cell entry. During these outages, remote tools and specialized shield plates were employed to minimize dose to workers. Mock-ups of non-routine maintenance activities were critical to early identification of potential issues and improvements, which shortened outage duration. Consistent with the facility's operational strategy, evolutions needed for MCU layup were identified and sequenced to ensure safe conditions within the facility, meet pre-defined criteria for lay-up configuration, and protect workers, while minimizing the impact to SWPF integration. De-inventory and flushing of process areas was prioritized so that the total residual inventory was reduced as efficiently as possible. This paper discusses lessons learned and best practices from troubleshooting unique issues, performing complex maintenance activities, and implementing a layup strategy that best supports the overall system mission. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2023

The Elevated-Temperature Cyclic Properties of Powder Metallurgy-Hot Isostatic Pressed 316H and 316L Stainless Steel

Section III, Division 5 of the American Society of Mechanical Engineers Boiler and Pressure Vessel Code covers construction rules for elevated-temperature nuclear components. Microreactor developers have expressed a need for advanced manufacturing processes to fabricate microreactor components to reduce manufacturing costs. Components fabricated using manufacturing processes other than conventional techniques are not currently qualified in Section III, Division 5. An expeditious approach to qualifying an advanced manufacturing process for alloys whose wrought-product form is already qualified in Division 5 is to demonstrate the resultant properties from the advanced manufacturing process are equivalent or superior to the wrought-product form. Powder metallurgy-hot isostatic pressing (PM-HIP) is a mature technology that offers many advantages that are attractive to the microreactor industry. Preliminary data show that the elevated-temperature creep-fatigue properties of PM-HIP 316H stainless steel (SS) are reduced compared to the Wrought 316H SS, which is qualified in Section III, Division 5. Work is ongoing to identify the mechanisms responsible for the reduced creep-fatigue properties and to establish acceptance criteria to confirm the adequacy of the component for service.

316H stainless steel↗

DOE OSTI2023

Super p-sulfur cathodes for quasi-solid-state lithium-sulfur-batteries

Lithium-Sulfur (Li-S) batteries have become a promising candidate to meet the current energy storage demand, with its natural abundance of materials, high theoretical capacity of 1672 mAhg-1, high energy density of 2600 Whkg-1, low cost and lower environmental impact. Sulfide based solid state electrolytes (SSEs) have received greater attention due to their higher ionic conductivity, compatible interface with sulfur-based cathodes, and lower grain boundary resistance. However, the interface between SSEs and cathodes has become a challenge in all solid-state Li-S batteries due to the rigidity of the participating surfaces. A hybrid electrolyte containing SSE coupled with a small amount of ionic liquid, was essential to improve the interface contact of the SSE with the electrodes. Coating-based cathodes were successfully fabricated using water-based carboxymethyl cellulose (CMC) solution and Styrene butadiene rubber (SBR) as the binder with low sulfur loading (0.70 mgcm-2) as well as high sulfur loading (4.0 mgcm-2). Solid-state composite powder-based cathodes pressed onto SSE (loading 4.0 mgcm-2) with enhanced electronic and ionic conductivity were fabricated with Super P: Sulfur (SP:S) and SSE. Ionic Liquids (IL) prepared using Lithium bis(trifluoromethyl sulfonyl)imide (LiTFSI) as salt, with premixed pyrrolidinium bis(trifluoromethyl sulfonyl)imide (PYR) as solvent and 1,3-dioxolane (DOL) as diluent were used to wet both SSE-electrode interfaces. The effect of IL dilution, co-solvent amount, LiTFSI concentration, C rate at which the batteries are tested and the effect of SSE inside the cathode, were systematically studied and optimized to develop a quasi-solid-state electrolyte Li-S battery (QSSLSB) with higher capacity retention and cyclability. LiTFSI (2M) dissolved in PYR:DOL(1:1) found to be optimum IL combination for low sulfur loading QSSLSBs reaching 500 mAh/g after 100 cycles while LiTFSI (3M) in PYR:DOL(1:3) was the optimum IL concentration for higher loading QSSLSBs reaching 400 mAh/g after 100 cycles. This work reports promising results of QSSLSB based on novel Li6PS5F0.5Cl0.5 Li-argyrodite solid-state electrolyte (SSE) with minute amount of IL, Super P-Sulfur (SP:S) cathode, and Li-anode. It also offers a new insight into the intimate interfacial contacts between the SSE and carbon-sulfur cathodes, which will be critical for improved electrochemical performance of quasi-solid-state lithium-sulfur batteries with high sulfur loading in the future.

25 ENERGY STORAGE↗

DOE OSTI2022

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↗

DOE OSTI2023

In situ embedment of type K sheathed thermocouples with directed energy deposition

Advanced nuclear reactor systems require new technologies for heat transfer and system monitoring. Additive manufacturing (AM) offers the design flexibility to allow in-situ sensor embedment through smart manufacturing for real-time monitoring, and performance of these systems. Here, this study focuses on experiments investigating the feasibility of in-situ sensor embedment using directed energy deposition (DED). Type K thermocouples are embedded into 316L stainless steel (SS) samples using two different configurations (e.g., exposed and embedded tips) and two designs (e.g., flush to substrate) within an AM base. Embedded sensor samples are analyzed via in-situ measurements and high-temperature performance validation tests at 350ºC and 900ºC. Temperature performance results at both temperature tests show good agreement with manufacturer specifications proving that these sensors could still capture accurate temperature readings after in-situ embedment during DED processing. An additional optimization experiment was conducted on the exposed tip configuration using a surrogate thermocouple to improve tolerances and the embedment process. Results improved tolerances, lower porosity, smaller gaps between the sensor and base, and better junction contact for the sensor. Although further optimization of this embedment strategy is necessary to improve the structural stability and tolerances within the component, this research strategy provides a proof-of-feasibility for DED embedment with commercial sheathed thermocouples. This research provides early impact on embedment of sensor for multiple materials and complex geometric components..

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2023

Evidence for current suppression in superconductor–superconductor bilayers

Superconducting radio frequency (SRF) cavities, which are critical components in many particle accelerators, need to be operated in the Meissner state to avoid strong dissipation from magnetic vortices. For a defect-free superconductor, the maximum attainable magnetic field for operation is set by the superheating field, B sh , which directly depends on the surface current. In heterostructures composed of different superconductors, the current in each layer depends not only on the properties of the individual material, but also on the electromagnetic response of the adjacent layers through boundary conditions at the interfaces. Three prototypical bilayers [Nb 1–x Ti x N (50 nm)/Nb, Nb 1–x Ti x N (80 nm)/Nb, and, Nb 1–x Ti x N (160 nm)/Nb] are investigated here by depth-resolved measurements of their Meissner screening profiles using low energy muon spin rotation (LE-µSR). From fits to a model based on London theory (with appropriate boundary and continuity conditions), a magnetic penetration depth for the thin Nb 1–x Ti x N layers of λ Nb 1–x Ti x N = 182.5(31) nm is found, in good agreement with literature values for the bulk alloy. Using the measured λ Nb 1–x Ti x N , the maximum vortex-free field, B max , of the superconductor-superconductor (SS) bilayer structure was estimated to be 610(40) mT. The strong suppression of the surface current in the Nb 1–x Ti x N layer suggests an optimal thickness of ~ 1.4λ Nb 1–x Ti x N = 261(14) nm.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2025

HPC for Optimizing Process Parameters to Control Material Evolution in Seamless Induction Hardening of Wind Turbine Main Shaft Bearings

Work proposed in this project focused on understanding the effect of martensitic transformation in the steel on the potential for cracking during seamless induction hardening (SIH) as a function of process conditions to allow the process to optimally scale up. Large-scale, three-dimensional phase-field simulations of martensitic transformation were performed using MEUMAPPS-SS (Microstructure Evolution Using Massively Parallel Phase-field Simulations – Solid State) code developed at Oak Ridge National Laboratory. The simulations were guided by location-specific thermal history generated by experimental measurements of time-temperature history generated at The Timken Company. The simulations were able to capture the morphological evolution of the martensite variants in an Fe-1.0C-1.5Cr steel based on the Nishiyama-Wasserman (NW) orientation relationship. The simulations were also able to quantify the stress-state at the interface between impinging martensite variants. The simulations indicated that the magnitude of the various stress and strain components were dependent on the sizes of the impinging plates with a reduction in these quantities with reduced plate size in agreement with experimental findings. The results obtained from the simulations will be used to guide the optimization of the alloy thermal conditions to eliminate quench cracking during SIH of bearing steels.

99 GENERAL AND MISCELLANEOUS↗