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NASA NTRS2026

A Dispersion-Strengthened Low-Density Niobium Alloy and Its Elevated Temperature Mechanical Performance

In response to the elevated-temperature and weight-reduction demands of modern aerospace applications, a novel oxide-dispersion-strengthened low-density niobium alloy (LDNb-ODS) was fabricated using laser powder bed fusion (L-PBF). To overcome powder procurement barriers, L-PBF feedstock was produced by blending commercial Nb521, Ti64, and Cr powder with Y2O3 nanoparticles via resonant acoustic mixing. Following L-PBF and a 1400°C vacuum heat treatment, the alloy achieved a density of 6.73 g/cc and a fine mean grain size of 4.62 µm stabilized by uniform ~30 nm yttria dispersoids. Microstructural analysis revealed a chemically inhomogeneous build with lack-of-fusion defects and a titanium (Ti) shift from a nominal 31.5 wt% in the starting powder blend to 24.8 wt% in the printed part due to preferential Ti loss during printing. Elevated-temperature tensile testing demonstrated that LDNb-ODS maintained a superior specific yield strength of 60-85 MPa/(g/cc) up to 800°C, outperforming nickel-based alloys Ni625, Ni230, and GRX-810. Between 870°C and 950°C, its specific strength surpassed both Ni718 and Ni625. In rapid stress-rupture testing at 1093°C and 20.7 MPa, uncoated LDNb-ODS survived 21.4 hours (a tenfold increase over legacy C-103) while an R512E silicide coating extended rupture life to 84.8 hours, confirming that oxidation accelerates low-stress failure. These findings demonstrate that additive manufacturing of LDNb-ODS provides a viable, lightweight alternative to nickel-based superalloys for high-temperature (>850°C) aerospace components.

Low Density Niobium Alloy↗

DOE OSTI2012

Micro-structural optimization of polybenzimidazole-based membranes for H2/CO2 separation at elevated temperatures

There is compelling need to develop novel separation methods to improve the energy efficiency of synthesis (syn) gas processing operations including H{sub 2} and H{sub 2}/CO production to meet power, chemicals, and fuel producer needs, as well as carbon capture and removal of other undesirable syngas impurities. To be technically and economically viable, a successful separation method must be applicable to industrially relevant gas streams at realistic process conditions and compatible with large gas volumes. H{sub 2} selective membrane technology is a promising method for syngas separations at elevated temperatures (>150 C) that could be positioned upstream or downstream of one or more of the water-gas-shift reactors (WGSRs) or integrated with a WGSR depending on application specific syngas processing. Polybenzimidazole (PBI)-based polymer chemistries are exceptional candidates for H{sub 2}/CO{sub 2} separations at elevated temperatures. In general, these materials possess excellent chemical resistance, very high glass transition temperatures (> 400 C), good mechanical properties, and an appropriate level of processability. Although commercially available PBI polymers have demonstrated commercially attractive H{sub 2}/CO{sub 2} selectivity, their H{sub 2} permeability is low. Our team s employing structural and chemical manipulations to tailor the polymer free-volume achitecture with the ultimate goal of enhancing H{sub 2} permselectivity while retaining the inherent hermochemical stability characteristics of PBI. We will discuss our synthetic approaches and their influences on the gas transport behavior of these PBI-based materials. In general, a decrease in H{sub 2}/CO{sub 2} selectivity was observed with an increase in H{sub 2} permeability. H{sub 2} permeability and H{sub 2}/CO{sub 2} selectivity at 250 C ranged from 50 to 1000 barrer and 5 to 45, respectively.

08 HYDROGEN↗

DOE OSTI2015

Apparatuses and methods of determining if a person operating equipment is experiencing an elevated cognitive load

A method of, and apparatus for, determining if a person operating equipment is experiencing an elevated cognitive load, wherein the person's use of a device at a first time is monitored so as to set a baseline signature. Then, at a later time, the person's use of the device is monitored to determine the person's performance at the second time, as represented by a performance signature. This performance signature can then be compared against the baseline signature to predict whether the person is experiencing an elevated cognitive load.

42 ENGINEERING↗

DOE OSTI2019

Methods for elevating fat/oil content in plants

In some embodiments, the present invention provides a method of elevating lipid content in vegetative (non-seed) plant or algae cells, plant tissues, or whole plants by genetically modifying the plant or algae to express a lipid droplet-associated protein or polypeptide (such as fat-specific protein 27) of mammalian origin. Also provided are genetically-modified plant or algae cells, plant tissues, or whole plants with elevated cellular lipid content, expressing a lipid droplet-associated protein or polypeptide (such as fat-specific protein 27) of mammalian (e.g. human) origin.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2012

Results from Evaluation of Representative ASME AG-1 Section FK Radial Flow Dimple Pleated HEPA Filters Under Elevated Conditions - 12002

The American Society of Mechanical Engineers (ASME) has recently added Section FK establishing requirements for radial flow HEPA filters to the Code on Nuclear Air and Gas Treatment (AG-1). Section FK filters are expected to be a major element in the HEPA filtration systems across the US Department of Energy (DOE) complex. Radial flow filters have been used in Europe for some time, however a limited amount of performance evaluation data exists with respect to these new AG-1 Section FK units. In consultation with a technical working group, the Institute for Clean Energy Technology (ICET) at Mississippi State University (MSU)has evaluated a series of representative AG-1 Section FK dimple pleated radial flow HEPA filters. The effects of elevated relative humidity and temperature conditions on these filters are particularly concerning. Results from the evaluation of Section FK filters under ambient conditions have been presented at the 2011 waste management conference. Additions to the previous test stand to enable high temperature and high humidity testing, a review of the equipment used, the steps taken to characterize the new additions, and the filter test results are presented in this study. Test filters were evaluated at a volumetric flow rate of 56.6 m{sup 3}/min (2000 cfm) and were challenged under ambient conditions with Alumina, Al(OH){sub 3}, until reaching a differential pressure of 1 kPa (4 in. w.c.), at which time the filters were tested, unchallenged with aerosol, at 54 deg. C (130 deg. F) for approximately 1 hour. At the end of that hour water was sprayed near the heat source to maximize vaporization exposing the filter to an elevated relative humidity up to 95%. Collected data include differential pressure, temperature, relative humidity, and volumetric flow rate versus time. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2020

Development of a Model Correlating Axial HEPA Filter Performance Between Elevated and Standard Conditions

The ASME AG-1 Code specifies minimum rated airflow based on standard cubic feet per minute (SCFM) for axial high efficiency particulate air (HEPA) filters and actual cubic feet per minute (ACFM) for radial HEPA filters with corresponding maximum pressure drop. A quantitative analysis can be performed to demonstrate the variation in filter efficiency and develop a correlation of performance between axial filters subjected to ACFM and SCFM. This study illustrates the variation in filter efficiency of axial HEPA filters subjected to ACFM and SCFM flow rate conditions at varying atmospheric pressures. It also presents the methods used to calculate correction factors to convert filter efficiency and pressure drop from elevated to standard conditions. The Axial Large Scale Test Stand (ALSTS) in the Institute for Clean Energy Technology (ICET) at Mississippi State University has been utilized to control aerosol concentration, flowrate, atmospheric pressure, relative humidity, and temperature. The filter test matrix consists of axial HEPA filters rated at 1,000 and 1,500 CFM with varying filter pack types. Each filter is subjected to varying pressures of 14.70 psi, 13.55 psi, 12.40 psi, and 11.25 psi, temperatures of 70 deg. F, 110 deg. F, and 150 deg. F, and relative humidities of 50% and 80%, resulting in twenty-four unique testing points. The corresponding SCFM flow rates are computed for each point in order to form a comparison. Evaluation of the effects of designating ACFM or SCFM will be based upon the filter efficiencies of generated Dioctyl Phthalate (DOP) particles at a diameter of 0.3 micrometers. The results show filter efficiency decreasing as atmospheric pressure decreases due to increased filter face velocity. A correlation model is developed to convert filter efficiency and pressure drop at elevated conditions to those of standard pressure, relative humidity, and temperature.

42 ENGINEERING↗

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 OSTI2024

Effectiveness of Vapor Corrosion Inhibitors Under Elevated Chloride Conditions for Aboveground Storage Tank Application

The sand quality used to construct the tank pad is an important contributing factor to the rate of corrosion that occurs on the soil-side of the aboveground storage tanks (ASTs) floor plates. Clean sand that meets specific criteria provides the first line of defense for mitigation of tank floor corrosion. However, it has been observed that the sand quality used for some existing tanks differ greatly from the specifications provided in the API 651 standard; this could be partially due to initial sand quality not meeting the specification, and partially due to the environmental effects over time. For example, rain-water intrusion could lead to higher than the specified contents of corrosive species such as chloride. Tank operators are increasingly using vapor corrosion inhibitors (VCIs) either as a stand alone or in combination with cathodic protection (CP) for ASTs to mitigate soil-side corrosion. VCIs are delivered either through-thefloor or injected through the ports in the ring wall. Experimental studies were conducted to evaluate VCIs’ performance at elevated chloride concentrations and to study the effectiveness of the delivery methods under extreme chloride conditions. The experimental work found that VCI performance is robust and not compromised due to high chloride levels, such as 300 ppm or more. The work also showed that the through-the-floor VCI delivery method is more beneficial compared to the through-the-sand-pad method when tank pad corrosivity is elevated.

Shukla, Pavan K.↗

DOE OSTI2026

A Physics-Based Digital Twin for Wave Elevation and Seabed Moment Estimation of Offshore Monopiles: Preprint

In this work, we present a proof of concept of a physics-based digital twin for a monopile structure (with overhead inertia) subjected to wave loading. The digital twin is formulated using reduced-order models derived from first principles and combined with a Kalman filter for state estimation. The proposed framework estimates the monopile top motion, the wave elevation, and the section forces and moments along the pile using primarily acceleration measurements at the monopile top. Key innovations include the use of a hydrodynamic shape function to represent distributed wave loading in a compact and computationally efficient manner, and the introduction of a shaping filter to augment the state-space with wave kinematics. Synthetic measurement data are generated using OpenFAST and used as a reference to assess the performance of the digital twin. Results demonstrate that the wave elevation can be accurately reconstructed without direct sea-state measurements as long as the wave regime is inertia-dominated. Under the ideal tested conditions, the total hydrodynamic force and sea-bed bending moment are estimated with relative errors on the order of 1% and correlation coefficients exceeding 96%. Future work will evaluate the estimator's performance under operational uncertainties and more complex loading conditions.

17 WIND ENERGY↗

DOE OSTI2013

Digital Elevation Model, 0.5 m, Barrow Environmental Observatory, Utqiagvik (Barrow), Alaska, 2012

This 0.5m horizontal resolution digital elevation model (DEM) was developed from Airborne Laser Altimetry flown by Aerometric Inc, now know as Quantum Spatial, Inc. on August 12, 2012. One Mission was flown and the data jointly processed with Los Alamos National Laboratory (LANL) personnel to produce a 0.5m DEM covering a region approximately 2.8km wide and 12.5km long extending from the coast above North Salt Lagoon to south of Gas Well Road. This DEM encompasses a diverse range of hyrdrologic, geomorphic, geophysical and biological features typical of the Barrow Peninsula. Vertical accuracy at the 95% confidence interval was computed as 0.145m. The coordinate system, datum, and geoid for this DEM are UTM Zone 4N, NAD83 (2011), NAVD88 (GEOID09). This dataset includes one .tif file and one .pdf file.The Next-Generation Ecosystem Experiments: Arctic (NGEE Arctic), was a research effort to reduce uncertainty in Earth System Models by developing a predictive understanding of carbon-rich Arctic ecosystems and feedbacks to climate. NGEE Arctic was supported by the Department of Energy's Office of Biological and Environmental Research.The NGEE Arctic project had two field research sites: 1) located within the Arctic polygonal tundra coastal region on the Barrow Environmental Observatory (BEO) and the North Slope near Utqiagvik (Barrow), Alaska and 2) multiple areas on the discontinuous permafrost region of the Seward Peninsula north of Nome, Alaska.Through observations, experiments, and synthesis with existing datasets, NGEE Arctic provided an enhanced knowledge base for multi-scale modeling and contributed to improved process representation at global pan-Arctic scales within the Department of Energy's Earth system Model (the Energy Exascale Earth System Model, or E3SM), and specifically within the E3SM Land Model component (ELM).

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2017

Digital Elevation Model, 0.25 m, Barrow Environmental Observatory, Utqiagvik (Barrow), Alaska, 2013

This 0.25m horizontal resolution digital elevation model (DEM) was developed from Airborne Laser Altimetry flown by Aerometric Inc, now known as Quantum Spatial, Inc. on July 12, 2013. One Mission was flown and the data jointly processed with LANL personnel to produce a 0.25m DEM covering a region approximately 2.8km wide and 12.4km long extending from the coast above North Salt Lagoon to south of Gas Well Road. This DEM encompasses a diverse range of hydrologic, geomorphic, geophysical and biological features typical of the Barrow Peninsula. Vertical accuracy at the 95% confidence interval was computed as 0.143m. The coordinate system, datum, and geoid for this DEM are UTM Zone 4N, NAD83 (2011), NAVD88 (GEOID09). This dataset includes a variety of file types.The Next-Generation Ecosystem Experiments: Arctic (NGEE Arctic), was a research effort to reduce uncertainty in Earth System Models by developing a predictive understanding of carbon-rich Arctic ecosystems and feedbacks to climate. NGEE Arctic was supported by the Department of Energy's Office of Biological and Environmental Research.The NGEE Arctic project had two field research sites: 1) located within the Arctic polygonal tundra coastal region on the Barrow Environmental Observatory (BEO) and the North Slope near Utqiagvik (Barrow), Alaska and 2) multiple areas on the discontinuous permafrost region of the Seward Peninsula north of Nome, Alaska.Through observations, experiments, and synthesis with existing datasets, NGEE Arctic provided an enhanced knowledge base for multi-scale modeling and contributed to improved process representation at global pan-Arctic scales within the Department of Energy's Earth system Model (the Energy Exascale Earth System Model, or E3SM), and specifically within the E3SM Land Model component (ELM).

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2020

SPRUCE Plot-Level Water Table Data Assessments for Absolute Elevations and Height with Respect to Mean Hollows Beginning in 2015

This data set provides a record of the half-hourly automated water table depth data collected for 12 SPRUCE plots (4, 6, 7, 8, 10, 11, 13, 14, 16, 17, 19, 20, and 21) beginning during deep peat heating (DPH) in 2015 and continuing throughout the whole ecosystem warming (WEW) manipulations for the SPRUCE Project (Hanson et al. 2017). The data currently cover 2015-05-12 through 2024-12-31 and will be updated periodically throughout the duration of the SPRUCE project. Also provided are daily plot normalized data for water table depths with respect to mean hollow locations within each plot. The hollow referenced data provide the basis for the intercomparison of peat saturation or aeration across treatment plots. A limited data set for manual water table observations made periodically from 2015-2022 are also provided as a reference to the plot center automated observations. In August 2015, WEW was initiated at 5 warming levels (+0, +2. +4.5, +6.75 and +9 °C) with 2 plots per warming level. DPH measurements were underway before the initiation of WEW heating treatments and both are expected to operate through 2025. Elevated CO2 treatments were added in June 2016 (Enclosures 4, 10, 11, 16 and 19). All measurements were made at the 8.1-ha S1 bog forest site in northern Minnesota, 40 km north of Grand Rapids, in the USDA Forest Service Marcell Experimental Forest (MEF). This dataset contains three data files in comma separated (*.csv) format.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2015

Elevated carbon dioxide is predicted to promote coexistence among competing species in a trait‐based model

Abstract Differential species responses to atmospheric CO 2 concentration (C a ) could lead to quantitative changes in competition among species and community composition, with flow‐on effects for ecosystem function. However, there has been little theoretical analysis of how elevated C a ( eC a ) will affect plant competition, or how composition of plant communities might change. Such theoretical analysis is needed for developing testable hypotheses to frame experimental research. Here, we investigated theoretically how plant competition might change under eC a by implementing two alternative competition theories, resource use theory and resource capture theory, in a plant carbon and nitrogen cycling model. The model makes several novel predictions for the impact of eC a on plant community composition. Using resource use theory, the model predicts that eC a is unlikely to change species dominance in competition, but is likely to increase coexistence among species. Using resource capture theory, the model predicts that eC a may increase community evenness. Collectively, both theories suggest that eC a will favor coexistence and hence that species diversity should increase with eC a . Our theoretical analysis leads to a novel hypothesis for the impact of eC a on plant community composition. This hypothesis has potential to help guide the design and interpretation of eC a experiments.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2022

Results from an international interlaboratory study on light‐ and elevated temperature‐induced degradation in solar modules

Abstract This paper reports the results of an international interlaboratory comparison study on light‐ and elevated temperature‐induced degradation (LETID) on crystalline silicon photovoltaic (PV) modules. A large global network of PV module manufacturers and PV testing laboratories collaborated to design a protocol for LETID detection and screen a large and diverse set of prototype modules for LETID. Results across labs indicate the reproducibility of LETID testing is likely within ±1% of maximum power (P MP ). In intentionally engineered LETID‐sensitive modules, mean degradation after the prescribed detection stress is roughly 6% P MP . In other module types the LETID sensitivity is smaller, and in some we observe essentially negligible degradation attributable to LETID. In LETID‐sensitive modules, both open‐circuit voltage (V OC ) and short‐circuit current (I SC ) degrade by a roughly similar magnitude. We observe, as do previous studies, that LETID affects each cell in a module differently. An investigation of the potential mismatch losses caused by nonuniform LETID degradation found that mismatch loss is insignificant compared to the estimated loss of cell I SC , which drives loss of module I SC . Overall, this work has helped inform the creation of a forthcoming standard technical specification for LETID testing of PV modules, IEC TS 63342 ED1, and should aid in the interpretation of results from that and other LETID tests.

14 SOLAR ENERGY↗

DOE OSTI2024

Constitutive model development of aluminum alloy 1100 for elevated temperature forming process

Commercially pure aluminum alloy, AA1100, presents good electrical and thermal conductivity, high formability, and low cost. Those favorable characteristics have the potential to enable bipolar plates with improved economics and enhanced performance compared to current stainless steel bipolar plates for proton exchange membrane fuel cells. An accurate constitutive model is essential to develop and optimize processing parameters and effectively control the forming process. Here, the objective of this work is to develop a constitutive model of AA1100 that is able to simulate stress-strain relation, formed geometry, and predict the onset of fracture strain to avoid forming failure. Initially, a set of tensile tests at temperature between 300 and 500°C and strain rate between 0.005 and 1.0/s were conducted to examine the deformation behavior. Then, a set of damage-based unified visco-plastic constitutive equations is proposed and calibrated based on the results of stress-strain data. A genetic algorithm optimization method is applied to search for best fitting material constants in constitutive equations. The proposed model shows good predictability of both the stress-strain relation and fracture strain at low strain rate and high temperature conditions. The accuracy of proposed model is also evaluated statistically. A comparison of the proposed model with three popular models (Arrhenius-type mode, Johnson-Cook model and Zerilli-Armstrong model) was made. The proposed model shows the best experimental agreement with correlation coefficient of 0.96 in contrast to 0.25, 0.38 and 0.75 for the popular models, respectively. The proposed model can help to optimize the elevated temperature forming process and guide die design to enable optimal geometric features in the formed components.

08 HYDROGEN↗

DOE OSTI2017

Shock Response of Commercial Purity Polycrystalline Magnesium Under Uniaxial Strain at Elevated Temperatures

Here, results of plate impact experiments designed to investigate the onset of incipient plasticity in commercial purity polycrystalline magnesium (99.9%) under weak uniaxial strain compression and elevated temperatures up to melt are presented. The dynamic stress at yield and post yield of magnesium, as inferred from the measured normal component of the particle velocity histories at the free (rear) surface of the target plate, are observed to decrease progressively with increasing test temperatures in the range from 23 to 500 °C. At (higher) test temperatures in the range 500–610 °C, the rate of decrease of dynamic stress with temperature at yield and post-yield in the sample is observed to weaken. At still higher test temperatures (617 and 630 °C), a dramatic increase in dynamic yield as well as flow stress is observed indicating a change in dominant mechanism of plastic deformation as the sample approaches the melt point of magnesium at strain rates of ~105/s. In addition to these measurements at the wavefront, the plateau region of the free surface particle velocity profiles indicates that the longitudinal (plastic) impedance of the magnesium samples decreases continuously as the sample temperatures are increased from room to 610 °C, and then reverses trend (indicating increasing material longitudinal impedance/ strength) as the sample temperatures are increased to 617 and 630 °C. Lastly, electron back scattered diffraction analysis of the as-received and annealed pre-test magnesium samples reveal grain coarsening as well as grain re-orientation to a different texture during the heating process of the samples.

36 MATERIALS SCIENCE↗

DOE OSTI2017

Dynamic Uniaxial Compression of HSLA-65 Steel at Elevated Temperatures

Here, the dynamic response of a high-strength, low alloy Grade 65 (HSLA-65) steel, used by the United States Navy for ship hull construction, is investigated under dynamic uniaxial compression at temperatures ranging from room temperature to 1000 °C using a novel elevated temperature split-Hopkinson pressure bar. These experiments are designed to probe the dynamic response of HSLA-65 steel in its single α-ferrite phase, mixed α + γ-austenite phase, and the single γ-austenite phase, as a function of temperature. The investigation is conducted at two different average strain rates—1450 and 2100/s. The experimental results indicate that at test temperatures in the range from room temperature to lower than 600 °C, i.e. prior to the development of the mixed α + γ phase, a net softening in flow strength is observed at all levels of plastic strain with increase in test temperatures. As the test temperatures are increased, the rate of this strain softening with temperature is observed to decrease, and at 600 °C the trend reverses itself resulting in an increase in flow stress at all strains tested. This increase in flow stress is understood be due to dynamic strain aging, where solute atoms play a distinctive role in hindering dislocation motion. At 800 °C, a (sharp) drop in the flow stress, equivalent to one-half of its value at room temperature, is observed. As the test temperature are increased to 900 and 1000 °C, further drop in flow stress are observed at all plastic strain levels. In addition, strain hardening in flow stress is observed at all test temperatures up to 600 °C; beyond 800 °C the rate of strain hardening isobserved to decrease, with strain softening becoming dominant at temperatures of 900 °C and higher. Moreover, comparing the high strain rate stress versus strain data gathered on HSLA 65 in the current investigation with those available in the literature at quasi-static strain rates, strain-rate hardening can be inferred. The flow stress increases from 700 MPa at 8 × 10 -4 /s to 950 MPa at 1450/s and then to 1000 MPa at 2100/s at a strain of 0.1. Finally, optical microscopy is used to understand evolution of microstructure in the posttest samples at the various test temperatures employed in the present study.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Additively manufactured Al-Ce-Ni-Mn alloy with improved elevated-temperature fatigue resistance

Here, the high cycle fatigue behavior of an additively manufactured (AM) Al-10.5Ce-3.1Ni-1.2Mn wt% alloy was evaluated at 350 °C. The measured fatigue strength of 50 MPa at this temperature is comparable to the most fatigue resistant wrought Al alloys (2618-T6 and 7079-T6) at 315 °C. Refinement of pore populations through advanced AM processing in the examined alloy led to oxide inclusions becoming dominant fatigue crack initiation sites. The distribution of microstructural features that determine crack initiation was measured by X-ray computed tomography and served as input to make fatigue strength model predictions with various methodologies. A Monte-Carlo based approach that was previously applied to predict the fatigue strength of cast aluminum alloys through pore size distributions yielded accurate predictions for the fatigue strength of this AM alloy. Given the tunability of defect distributions in AM alloys, the sensitivity of the Al-Ce-Ni-Mn alloy fatigue behavior to defect distributions and outstanding elevated-temperature fatigue resistance of this alloy; the results together suggest the possibility of a new generation of fatigue-resistant alloys produced by the additive manufacturing route.

36 MATERIALS SCIENCE↗