Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “primary control”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 739 records · Page 41
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Role of Material Condition in Precursor Corrosion Damage and Stress Corrosion Crack Initiation Behavior of Alloy 600 in PWR Primary Water

Stress corrosion crack (SCC) initiation testing has been performed on a 15% cold-worked UNS N06600 (Alloy 600) heat in the mill-annealed (MA), solution annealed (SA), and thermally treated (TT) conditions to assess the role of grain boundary (GB) carbides on stress-assisted intergranular attack (IGA) and short crack nucleation and growth. The SCC initiation tests were conducted at constant load equivalent to materials yield stress in 360oC simulated PWR primary water with dissolved hydrogen at the Ni/NiO stability line. Results revealed the highest SCC initiation susceptibility in the Alloy 600 MA material followed by the TT and SA materials, suggesting the GB carbide distribution did not have a controlling effect on SCC initiation resistance. Quantitative assessments were conducted on IGA and short cracks to help understand this phenomenon and the role of GB carbides on precursor damage development that lead to differences in macroscopic SCC initiation behavior are discussed.

Zhai, Ziqing↗
DOE OSTI2024

Integrated Thermal Energy Storage and Brayton Cycle Equipment Demonstration (Integrated TESTBED) Project Design Basis

The Integrated Thermal Energy Storage and Brayton cycle Equipment Demonstration (Integrated TESTBED) project seeks to retire commercial-scale risks associated with the design, integration,and operation of a supercritical carbon dioxide (sCO2) power cycle and concentrating solar power (CSP) thermal energy storage (TES) system. This requires an understanding of commercial-scale collector system transient impacts on the TES system, the dynamics of heat exchange from theTES to the power cycle, and the control and operation of the power cycle to accommodate various dispatch strategies. In order to retire these risks, Heliogen has proposed to construct a 5 MWe CSP demonstration facility based on directly heated particle and sCO2 technology. The receivers, primary heat exchanger, and power cycle will be deployed at a full commercial scale based on Heliogen’s modular plant architecture to ensure actual system integration risks are validated during design, construction, and operation. This work summarizes the design basis for the Integrated TESTBED project demonstration facility including a design target for capacity factor to support test operations, hours of storage, particle silo arrangement, centrifugal article receivers, a diffusion bonded particle-sCO2 heat exchanger, and a 5 MWe (net) integrally geared sCO2 recompression Brayton cycle.

14 SOLAR ENERGY↗
DOE OSTI2020

Building commissioning costs and savings across three decades and 1500 North American buildings

B.V. Building commissioning (Cx) is a process for assuring efficient building operations that can be applied to new construction and existing buildings, resulting in energy and non-energy benefits. Quantifying the benefits of commissioning is challenging, but a 2009 study of 643 commercial buildings provided a solid initial data set to which we added 839 additional buildings for a significantly expanded and updated meta-analysis representing 34.7 million square meters (373 million square feet) of floor area. Since 2009 the commissioning industry has continued to grow, driven by building codes, utility programs, and rising awareness of commissioning benefits. In parallel, building controls have become more sophisticated, and analytics software has emerged to assist with commissioning. We find that delivery mechanism and market segment are key determinants of outcomes, although significant and cost-effective savings are found across the spectrum. Median primary energy savings for Cx projects in existing buildings ranged from 5 percent for those conducted under utility programs, 9 percent for monitoring-based commissioning utility programs (i.e., augmented with submetering and diagnostics), and 14 percent for Cx projects outside of utility programs. Across all project types, median savings ranged from 3 percent for the lodging market segment to 16 percent for public order and safety facilities. Outcomes did not vary significantly by building size or by market segment. Energy savings are rarely estimated for new construction commissioning. We found that the median costs of Cx were lower for the 2018 sample than for the 2009 sample—$\$$2.85 per square meter ($\$$0.26 per square foot) for existing buildings (a 33 percent reduction) and $\$$8.78 per square meter ($\$$0.82 per square foot) for new construction (a reduction of almost 50 percent). The median simple payback time for existing buildings was 1.7 years, with a 25th–75th percentile range of 0.8–3.5 years. Overall, this article summarizes these and other key findings, and discusses how the 2018 data reflects shifts in commissioning practice and outcomes.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Improving initialization and evolution accuracy of cosmological neutrino simulations

Neutrino mass constraints are a primary focus of current and future large-scale structure (LSS) surveys. Non-linear LSS models rely heavily on cosmological simulations — the impact of massive neutrinos should therefore be included in these simulations in a realistic, computationally tractable, and controlled manner. Here, a recent proposal to reduce the related computational cost employs a symmetric neutrino momentum sampling strategy in the initial conditions. We implement a modified version of this strategy into the Hardware/Hybrid Accelerated Cosmology Code (HACC) and perform convergence tests on its internal parameters. We illustrate that this method can impart Script $\mathcal{O}$(1%) numerical artifacts on the total matter field on small scales, similar to previous findings, and present a method to remove these artifacts using Fourier-space filtering of the neutrino density field. Moreover, we show that the converged neutrino power spectrum does not follow linear theory predictions on relatively large scales at early times at the 15% level, prompting a more careful study of systematics in particle-based neutrino simulations. We also present an improved method for backscaling linear transfer functions for initial conditions in massive neutrino cosmologies that is based on achieving the same relative neutrino growth as computed with Boltzmann solvers. Our self-consistent backscaling method yields sub-percent accuracy in the total matter growth function. Comparisons for the non-linear power spectrum with the Mira-Titan emulator at a neutrino mass of m ν = 0.15 eV are in very good agreement with the expected level of errors in the emulator and in the direct N-body simulation.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2026

AQDrop Quantum Service (AQDrop) v1.0

AQDrop is a job management system designed to streamline access to the Advanced Quantum Testbed (AQT) at NERSC (National Energy Research Scientific Computing Center). It serves as a centralized middleware layer between researchers and quantum processing hardware. Key Features: AQDrop provides a FastAPI-based server backed by PostgreSQL for job submission, queue management, and role-based access control (members, operators, and administrators). Users submit Qiskit circuits via JSON payloads, which are queued, dispatched to the QPU through the Qubic API, and returned as measurement counts. A Python client library and web dashboard round out the interface options. Primary Use: Researchers submit quantum circuit jobs from a laptop or login node; an operator client executes those jobs on the AQT's physical QPU and returns results — all coordinated through the central API. Advantages: Compared to ad-hoc or direct hardware access, AQDrop adds structured queue management, auditable job-status tracking and OAuth2 authentication — reducing scheduling conflicts and unauthorized access. Its containerized deployment also improves reproducibility and scalability. Overall, AQDrop functions as a purpose-built quantum job broker tailored to NERSC's specific hardware and institutional access requirements.

Caplinger, Evan [Lawrence Berkeley National Labora↗
DOE OSTI2020

Solubility Testing to Support the Addition of Sodium Reactor Experiment Material to Sludge Batch 10

The Savannah River Site H-Canyon Facility is planning to discard dissolved Sodium Reactor Experiment (SRE) material into Tank 51 prior to Sludge Batch 10 (SB10). SB10 with the SRE material will be processed in the Defense Waste Processing Facility (DWPF) using the Nitric-Glycolic Acid (NGA) flowsheet. The DWPF Nuclear Criticality Safety Evaluation (NCSE) protects a 14:1 mass ratio of manganese to equivalent uranium-235 in both the solid and liquid phases during processing by requiring a 70:1 mass ratio in the feed. A concern was raised that freshly precipitated manganese in the SRE material will behave differently from the manganese in sludge during DWPF processing and potentially invalidate the criticality control. To mitigate risks to the DWPF criticality controls, the Savannah River National Laboratory (SRNL) performed a metals solubility test applicable to recently precipitated manganese and uranium, as would be expected with SRE transfers to SB10. The objective of this analysis is the tracking of partitioning of the primary fissile component (uranium-235) with the credited poison (manganese) between the aqueous and insoluble phases.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

RELAP5-3D Modeling of High Temperature Test Facility (HTTF) Test PG-26

The High Temperature Test Facility (HTTF) at Oregon State University (OSU) is a scaled integral effects experiment designed to investigate transient behavior in high-temperature gas-cooled nuclear reactors with prismatic fuel and reflector blocks. Several tests have been completed, and more are still planned to at the HTTF, including depressurized conduction cooldown (DCC) and pressurized conduction cooldown (PCC) transients. This report analyses test PG-26, a progression of the Double Ended Inlet-Outlet Crossover Duct Break transient that is referred to as a DCC. PG-26 has been performed at the HTTF between May 30 and June 30, 2019. Core initial conditions (i.e., before the DCC started) have been met using low power (<100 kW) and two of ten available electric heaters. The DCC transient was initiated during the 50 th hour of the test. The break valves were opened, and hot helium from the core and cold helium from the reactor cavity simulation tank (RCST) started mixing. The gases flowed in a countercurrent fashion, where the top half of the hot duct contained hot helium that flowed in one direction and cold helium that flowed in the other direction in the bottom half of the duct. After the pressure and density reached equilibrium, the event entered a diffusion mode. The onset of a reverse natural circulation was not observed during the DCC period of the test. Version 4.4.2ie of the RELAP5-3D computer code has been used to model the HTTF PG-26 test, and results have been compared to available high-quality measured data. The model used in this study is the quality-controlled HTTF RELAP5-3D model (HTTF base 2018-04-19 QA), originally developed by P. Bayless. The report includes RELAP5-3D results of the “base calculations” as well as some sensitivities to important uncertain model inputs, such as primary helium mass flow rate, core ceramic thermal properties, as well as heat evacuation and loop friction models. Using the base RELAP5-3D model predicts a countercurrent helium flow in the hot duct observed at the beginning of the DCC, but instead of going into a molecular diffusion mode, the model predicts the onset of natural convection. Increasing friction in the core and hot duct prevents the natural convection from happening in some of the simulations. Although some temperatures are well predicted (and even overpredicted), the general tendency is to underpredict the ceramic and helium temperatures and heat removal rates during the DCC, resulting in many of the assessment findings being in minimal or insufficient agreement with the data. It is worth noting that the described discrepancies between measured data and RELAP5-3D predictions are not RELAP5-3D code limitations. More so, they reflect limitations in boundary condition and thermal property knowledge. While the RELAP5-3D calculations of the test provide some insights into what happens during the transient, and point to missing or potentially uncertain data to which the experimenters can direct their attention, the principal conclusion is that the PG-26 test data are insufficient for a system code assessment.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

High Voltage Regrown GaN P-N Diodes Enabled by Defect and Doping Control

This project studied and implemented methods to form GaN p-n diodes using selective area regrowth to achieve selective area doping. Successful selective area doping of GaN p-n diodes is an enabling factor to realize more advanced devices such as vertical transistors. The general challenge to selective area regrowth of GaN is that the primary etch method, inductively coupled plasma (ICP), damages the crystal and causes high leakage when didoes are formed by regrowth on the etched surface. Our approach used low damage etch methods following ICP etch to remove crystal damage and reduced leakage in the regrown diode. This project demonstrated 1.6 kV etched-and-regrown GaN p-n diodes using planar (non-selective) regrowth and 840 V etched-and-regrown p-n diodes using selective area regrown. Enabling factors were use of a low-damage reactive ion etch (RIE) to remove damage caused by the primary ICP etch combined with a multi-step junction terminal extension (JTE) process. Deep level defect investigation quantitatively correlated a deep level near the middle of the GaN band gap with ICP etch-induced leakage that was greatly mitigated by using a slow, low damage RIE process. This research is economically feasible for commercialization because the processes used in this project, including substrate type and source, epitaxial crystal growth and fabrication techniques are all standard to the GaN semiconductor industry. The fundamental understanding and foundational ability to produce kV-class GaN p-n diodes through etch-and-regrowth provides a path to realize high power, high efficiency GaN power switches that can significantly outperform commercial devices for next-generation electrical power conversion and transmission systems.

36 MATERIALS SCIENCE↗
DOE OSTI2022

A robust deep learning workflow to predict multiphase flow behavior during geological C O 2 sequestration injection and Post-Injection periods

Simulation of multiphase flow in porous media is essential to manage the geologic CO 2 sequestration (GCS) process, and physics-based simulation approaches usually take prohibitively high computational cost due to the nonlinearity of the coupled physics. This paper contributes to the development and evaluation of a deep learning workflow that accurately and efficiently predicts the temporal-spatial evolution of pressure and CO 2 plumes during injection and post-injection periods of GCS operations. Based on a Fourier Neural Operator, the deep learning workflow takes input variables or features including rock properties, well operational controls and time steps, and predicts the state variables of pressure and CO 2 saturation. To further improve the predictive fidelity, separate deep learning models are trained for CO 2 injection and post-injection periods due to the difference in primary driving force of fluid flow and transport during these two phases. We also explore different combinations of features to predict the state variables. We use a realistic example of CO 2 injection and storage in a 3D heterogeneous saline aquifer, and apply the deep learning workflow that is trained from physics-based simulation data and emulate the physics process. Through this numerical experiment, we demonstrate that using two separate deep learning models to distinguish post-injection from injection period generates the most accurate prediction of pressure, and a single deep learning model of the whole GCS process including the cumulative injection volume of CO 2 as a deep learning feature, leads to the most accurate prediction of CO 2 saturation. For the post-injection period, it is key to use cumulative CO 2 injection volume to inform the deep learning models about the total carbon storage when predicting either pressure or saturation. The deep learning workflow not only provides high predictive fidelity across temporal and spatial scales, but also offers a speedup of 250 times compared to full physics reservoir simulation, and thus will be a significant predictive tool for engineers to manage the long-term process of GCS.

58 GEOSCIENCES↗
DOE OSTI2024

Climate, Hydrology, and Nutrients Control the Seasonality of Si Concentrations in Rivers

Abstract The seasonal behavior of fluvial dissolved silica (DSi) concentrations, termedDSi regime, mediates the timing of DSi delivery to downstream waters and thus governs river biogeochemical function and aquatic community condition. Previous work identified five distinct DSi regimes across rivers spanning the Northern Hemisphere, with many rivers exhibiting multiple DSi regimes over time. Several potential drivers of DSi regime behavior have been identified at small scales, including climate, land cover, and lithology, and yet the large‐scale spatiotemporal controls on DSi regimes have not been identified. We evaluate the role of environmental variables on the behavior of DSi regimes in nearly 200 rivers across the Northern Hemisphere using random forest models. Our models aim to elucidate the controls that give rise to (a) average DSi regime behavior, (b) interannual variability in DSi regime behavior (i.e., Annual DSi regime), and (c) controls on DSi regime shape (i.e., minimum and maximum DSi concentrations). Average DSi regime behavior across the period of record was classified accurately 59% of the time, whereas Annual DSi regime behavior was classified accurately 80% of the time. Climate and primary productivity variables were important in predicting Average DSi regime behavior, whereas climate and hydrologic variables were important in predicting Annual DSi regime behavior. Median nitrogen and phosphorus concentrations were important drivers of minimum and maximum DSi concentrations, indicating that these macronutrients may be important for seasonal DSi drawdown and rebound. Our findings demonstrate that fluctuations in climate, hydrology, and nutrient availability of rivers shape the temporal availability of fluvial DSi.

Environmental Sciences & Ecology↗
DOE OSTI2020

Creation of discrete active site domains via mesoporous silica poly(styrene) composite materials for incompatible acid–base cascade reactions

This work highlights the design and synthesis of bifunctional mesoporous silicate – polymer composite dual acid–base supported cascade catalysts. Compartmentalization of the two incompatible active sites is sought by segregating acid sites on the silica surface, and base sites within polymer chains and/or polymer domains. The ability to isolate and segregate active sites via control of the mesoporous silica pore size and polymer molecular weight is probed with silica samples functionalized by a grafting-to process. Supplemental activator and reducing agent (SARA) atom transfer radical polymerization is used to synthesize random copolymers containing protected primary amines. Thiol–ene ‘click’ chemistry facilitates silica functionalization via a convergent approach, with the ene-functionalized polymer end group and silica-grafted thiols forming SBA/MCM-SH-poly(styrene-co-2-(4-vinylbenzyl)isoindoline-1,3-dione). Polymer deprotection and thiol oxidation produces primary amine/sulfonic acid containing composite catalysts. With the polymer supported Lewis base and silica grafted Brønsted acid, the two-step deacetalization – Knoevenagel condensation cascade is explored to assess the ability of these polymer/silica hybrids to segregate active sites, allowing both acid and base site accessibility. Six composite catalysts are synthesized and tested in individual and cascade reactions with kinetic results demonstrating that lower molecular weight SBA-15-P1 and MCM-41-P1 catalysts outperform (higher turnover frequencies and initial rates) their higher molecular weight analogues, as well as a polymer-free system containing molecular active sites dispersed on the silica surface. Higher molecular weight composite catalysts perform more poorly due to limited chain solubility, mass transfer limitations, and poor catalyst accessibility. In many cases, the polymer chains effectively thread into the mesopores, with higher molecular weight polymers leading to pore blockage and inhibited mass transfer.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Nonlinear coupling of whistler waves to oblique electrostatic turbulence enabled by cold plasma

Kinetic simulations and theory demonstrate that whistler waves can excite oblique, short-wavelength fluctuations through secondary drift instabilities if a population of sufficiently cold plasma is present. The excited modes lead to heating of the cold populations and damping of the primary whistler waves. The instability threshold depends on the density and temperature of the cold population and can be relatively small if the temperature of the cold population is sufficiently low. Furthermore, this mechanism may thus play a significant role in controlling amplitude of whistlers in the regions of the Earth's magnetosphere where cold background plasma of sufficient density is present.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2026

Integrated Magnetics for Multiport Inductive and Conductive Power Transfer Architecture for Electric Vehicles

This paper proposes a shared magnetic arrangement for an electric-vehicle charger that supports both conductive and inductive charging while preserving independent power control at the two ports. In the proposed implementation, the high-frequency transformer used for the conductive path and the resonant inductor required by the inductive path are realized in an integrated form. By combining the magnetic structure and primary-side converter hardware, the charger can deliver improved hardware utilization and higher power density without a corresponding increase in cost or implementation complexity. The paper describes the magnetic realization and presents finite-element and circuit-level simulation results to confirm minimal interaction between the two charging paths. The study demonstrates that the proposed charger is a viable option for flexible, high-power EV charging systems.

Mukherjee, Subho [ORNL] (ORCID:0009000672297925)↗
DOE OSTI2023

SDSS-IV MaNGA: The Effect of Stellar Mass and Halo Mass on the Assembly Histories of Satellite Galaxies

We combine an unprecedented MaNGA sample of over 3000 passive galaxies in the stellar mass range 10 9 –10 12 M ⊙ with the Sloan Digital Sky Survey group catalog by Tinker to quantify how central and satellite formation, quantified by radial profiles in stellar age, [Fe/H], and [Mg/Fe], depends on the stellar mass of the galaxy (M * ) and the mass of the host halo (M h ). After controlling for M * and M h , the stacked spectra of centrals and satellites beyond the effective radius (r e ) show small, yet significant differences in multiple spectral features at the 1% level. According to spectral fitting with the code alf , a primary driver of these differences appears to be [Mg/Fe] variations, suggesting that stellar populations in the outskirts of satellites formed more rapidly than the outer populations of centrals. To probe the physical mechanisms that may be responsible for this signal, we examined how satellite stellar populations depend on M h . We find that satellites in high-M h halos show older stellar ages, lower [Fe/H], and higher [Mg/Fe] compared to satellites in low-M h halos, especially for M * = 10 9.5 –10 10.5 M ⊙ . These signals lend support to environmentally driven processes that quench satellite galaxies, although variations in the merger histories of central and satellite galaxies also emerge as a viable explanation.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2025

The Impact of Cultural Values and Organizational Processes on Nuclear Security Operations

Human performance is a pivotal factor in the design, testing, maintenance, and operation of security systems. The effectiveness of these systems relies not only on the capabilities, limitations, motives, and attitudes of the individuals involved, but also on the quality of training, instructional content, and evaluation methods provided. To uphold security standards, seamless integration between technologies and operators necessitates reliable human input. In security operations, human errors, often attributed to blame, sanctions, low motivation, individual accountability, or complacency, are primary causes of system failures. Complacency, characterized by a false sense of security, reflects a lack of awareness of potential threats and is a significant contributing factor to lapses in security. Security incidents arise from various factors, many extend beyond individual control, highlighting the need for a holistic approach to human performance that integrates organizational processes and team collaboration. Historically, errors have been attributed to individual moral or cognitive failures. However, insights from Operational Experiences (OEs) suggest that organizational processes weakness and deficiencies in nuclear cultural values contribute more significantly to security failures than individual mistakes. This paper consolidates lessons learned from diverse international nuclear security cultures and aims to highlight the importance of security culture in shaping global perspectives on nuclear security. It underscores the role of cultural values in shaping nuclear security practices and enhancing the resilience of security systems in the nuclear sector.

Zineddin, Dr. Z. [ORNL] (ORCID:0009000848740725)↗
DOE OSTI2022

Review of Wave Energy Converter Power Take-Off Systems, Testing Practices, and Evaluation Metrics: Preprint

While the field of wave energy has been the subject of numerical simulation, scale model testing, and precommercial project testing for decades, wave energy technologies remain in the early stages of development and must continuing proving themselves as a promising modern renewable energy field. One of the difficulties that wave energy systems have been struggling to overcome is the design of highly efficient energy conversion systems that can convert the mechanical power, derived from the oscillation of wave activated bodies, into another useful product. Often the power take-off (PTO) is defined as the single unit responsible for converting mechanical power into another usable form such as electricity, pressurized fluid, compressed air, and others. The PTO, and the entire power conversion chain (PCC), is of great importance as it affects not only how efficient wave power is converted into electricity, but also contributes to the mass, size, structural dynamics, and levelized cost of energy (LCOE) of the wave energy converter (WEC). Unlike wind and solar, there is no industrial standard device, or devices, for wave energy conversion and this diversity is transferred to the PTO system. The majority of current WEC PTO systems incorporate a mechanical or hydraulic drive train, power generator, and an electrical control system. The challenge of WEC PTO designs is designing a mechanical-to-electrical component that can efficiently convert irregular, bi-directional, low frequency and low alternating velocity wave motions. While gross average power levels can be predicted in advance, the variable wave elevation input has to be converted into smooth electrical output and hence usually necessitates some type of energy storage system, such as battery storage, accumulator super capacitors, etc., or other means of compensation such as an array of devices. One of the primary challenges for wave energy converter systems is the fluctuating nature of wave resources, which require WEC components to be designed to handle loads (i.e. torques, forces, and powers) that are many times greater than the average load. This approach requires a much greater PTO capacity than the average power output and indicates a higher cost. In addition, supporting mechanical coupling and or gearing can be added to the PCC to help alleviate the difficulties with transmission and control of fluctuating large loads with low frequencies (indicative of wave forcing) into smaller loads at higher frequencies (optimum for conventional electrical machine design) can quickly increase the complexity of the PCC which could result in a greater number of failure modes and increased maintenance costs. All of the previous points demonstrate how the PTO influences WEC dynamics, reliability, performance and cost which are critical design factors. This paper further explores these topics by providing a review of the state-of-the-art PTO systems currently under development, how these novel PTO systems are tested and derisked prior to precommercial deployment, and the evaluation metrics historically used to differentiate between PTO designs and how they can be improved to support control co-design focused development of wave energy systems.

laboratory testing↗
DOE OSTI2025

Packing fraction control during additive manufacturing of powder green bodies

The demand for high performance ceramic and metal components with complex geometry necessitates developments in powder handling and green body shaping. Here, in this study, vibrational powder deposition is adapted to three-dimensional printing with the ability to modulate packing fraction during printing. Boron carbide powder with sub-micron primary particle size is printed over a packing fraction range of 25.0 % to 46.5 % (below the poured density to above the tapped density). Solid metal powders are printed at 67.5 %, which enables novel freestanding, vertical-walled features without binder. These capabilities introduce opportunities for more complex geometries in high-performance materials, e.g. large-scale uniaxial hot-pressing of ceramic ballistic armor components with graded thickness and three-dimensional curved or stepped features (by compensating for displacement differences during compaction). This technology also enables multi-material patterning of additive manufacturing powder beds with reduced feedstock quantity requirements and wastage.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Mechanisms for high creep resistance in alumina forming austenitic (AFA) alloys

Castable alumina forming austenitic (AFA) alloys have demonstrated superior creep life and oxidation resistance at temperatures exceeding 800⁰C. Despite the success in the applicability of these alloys in extreme environments, there is a limited understanding of the deformation modes and the influence of each alloying element guiding the alloy design strategies that could further enhance the creep strength of these AFA alloys, particularly at temperatures at and above 900⁰C. In this study, we reveal the mechanism underpinning the superior creep performance of castable AFA alloys that involves suppressing primary carbide formation through minor compositional modification. This approach results in a three-fold increase in creep strength at 900⁰C and 50 MPa. Here, by employing integrated characterization techniques, we analyzed the microstructures of two AFA alloys, both before and after the creep process. We discovered that the suppression of primary carbides permits the in-situ clustering of now-available interstitial elements such as C, Si, and O during high-temperature creep. This improved solid solution strengthening and reduced stacking fault energy of the alloy. Moreover, it also enabled controlled secondary carbide formation during testing, further improving the creep resistance. These findings underline the important interplay between alloy composition, microstructure, and creep properties, and offer a promising design strategy for developing economical high-temperature Fe-based alloys suitable for advanced applications.

36 MATERIALS SCIENCE↗