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All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Wyandotte Integrated Renewable Energy Strategy (WIRES 2) (Final Technical Report)

Wyandotte Municipal Services (WMS), a Michigan Municipal Utility offering electric generation, transmission & distribution, water filtration & distribution and Broadband/Video sought to deploy a set of renewable energy projects for their Electric Utility that contributed to reducing the City’s environmental and energy impact, provided examples that would encourage businesses and citizens to adopt cleaner energy practices and help WMS meet the required renewable energy standards of the State of Michigan (10% in 2015, 15% in 2021). WMS generates and delivers roughly 280,000 megawatt hours (MWh) of electricity annually to more than 10,000 homes and 1,000 businesses within the City of Wyandotte. The Wyandotte Integrated Renewable Energy Strategy – WIRES 2 resulted in deployment of a set of community-scale micro-wind turbines, evaluation and installation of energy-efficient and low-maintenance light-emitting diode (LED) street lights and park lights in highly visible locations in the City and expansion of the geothermal heating and cooling district that already included residential geothermal systems, to include larger scale business/institutional systems at the Utility’s largest electric customer and at the City Library. Finally, WMS identified the need for job training in energy efficiency and renewable energy technologies to further develop a local skilled workforce in these areas. Partially funded by the grant, the wind turbine project provides a benchmark for WMS, local businesses and residents in the evaluation of utility-scale wind v. micro-wind in an urban environment as a renewable energy strategy. Also partially funded by the grant, the LED project benefited the City of Wyandotte by reducing load on the electric system for the public utility but also reduced City costs for streetlighting, parking lot lighting and park lighting without a compromise in security. The project also resulted in a visual success that has led to additional approvals for non-Grant related LED lighting installations resulting in further reduction in the electric load in the City. Commercial Geothermal installations resulted in the Utility being able to eliminate steam customers who formerly utilized the byproduct of steam from WMS electric production. Due to the reduction in natural gas prices and the overall reduction in market purchased power, it was no longer feasible for WMS to operate its Power Plant as a base load plant and to only operate on a market dispatch philosophy when market prices dictated that WMS could produce electricity cheaper than the market purchase price. This has resulted in fewer operating days for the WMS Power Plant, resulting in less environmental impact. WMS has now completely exited the steam business and the ability to offer a geothermal option to two (2) former steam customers (BASF-Wyandotte and the Bacon Memorial Library) allowed for that. In addition, peak loads have been shaved for these two (2) large customers due to the consistent temperature offered by geothermal heating and cooling, reducing the swings associated with thermostat changes caused by outside temperature changes during extreme high and low temperatures. Finally, energy efficiency and renewable energy college-level classes at Wayne County Community College allowed a group of interested students to pursue studies in those technologies through grant provided tuition, books and course materials. This effort provided a foundation of potential future employees not only for WMS but other energy efficiency/renewable energy employers such as Franklin Energy, a partner with WMS in energy optimization efforts with Wyandotte businesses.

17 WIND ENERGY↗
NASA NTRS2019

Air Pollution Inputs to the Mojave Desert By Fusing Surface Mobile and Airborne in Situ and Airborne and Satellite Remote Sensing: A Case Study of Interbasin Transport With Numerical Model Validation

Deserts are fragile and highly sensitive ecosystems that increasingly are affected by upwind urban areas and industrial activities. The Los Angeles Basin (LAB) contributes to poor air quality in downwind deserts including the Mojave Desert. Few studies have investigated potential air pollution inputs to the Mojave, whose fragile ecosystem includes endangered plant and animal species. Data were collected on 19 August 2015 by a mobile air quality laboratory, AMOG (AutoMObile trace Gas) Surveyor, that observed inputs can arise from the LAB as well as the San Joaquin Valley (SJV), California. The campaign used a strong methane (CH4) plume as a tracer for the downwind fate of emissions from Bakersfield area petroleum production and also measured ozone (O3). Additional in situ concurrent airborne GHG and O3 data were collected by AJAX - Alpha Jet Atmospheric eXperiment. Both AMOG and AJAX measure winds. Mojave Desert air quality was very poor (visibility ~4 km). Based on the winds, an additional source was inferred beyond the LAB and SJV Basins. Numerical transport modeling and analysis of aerosol lidar data collected the same day by the Cloud Profiling LiDAR onboard the Earth Research-2 stratospheric airplane demonstrated that fires in Northern California were responsible, with prevailing winds transporting air southwards along the eastern Sierra Nevada Range (Bishop Valley) to the Mojave. Whereas the southern and eastern Mojave are impacted by SJV and LAB outflow, the north Mojave generally avoids these inputs. This study shows it can be affected by even distant wildfires, which likely will increase in occurrence and intensity from climate change. Thus, regulatory efforts to reduce air quality impacts on the endangered Mojave ecosystem must include wildfires and also account for the significant differences between different regions of the Mojave. Currently, there is a paucity of studies, highlighting the critical need for field research.

Ira Leifer↗
NASA NTRS1961

An Analytical Treatment of Aircraft Propeller Precession Instability

An analytical investigation is made of a precession-type instability which can occur in a flexibly supported aircraft-engine-propeller combination. By means of an idealized mathematical model which is comprised of a rigid power-plant system flexibly mounted in pitch and yaw to a fixed backup structure, the conditions required for neutral stability are determined. The paper also examines the sensitivity of the stability boundaries to changes in such parameters as stiffness, damping, and asymmetries in the engine mount, propeller speed, airspeed, Mach number, propeller thrust, and location of pitch and yaw axes. Stability is found to depend strongly on the damping and stiffness in the system. With the use of nondimensional charts, theoretical stability boundaries are compared with experimental results obtained in wind-tunnel tests of an aeroelastic airplane model. In general, the theoretical results, which do not account for wing response, show the same trends as observed experimentally; however, for a given set of conditions calculated airspeeds for neutral stability are consistently lower than the measured values. Evidently, this result is due to the fact that wing response tends to add damping to the system.

Reed, Wilmer H., III↗
DOE OSTI2026

Out With the Old: Empirical Trends in U.S. Land‐Based Wind Turbine Decommissioning and Repowering

A growing number of wind turbines (WTs) across the globe are now reaching or exceeding their expected service lifetime; WT decommissioning is on the rise. Accordingly, questions pertaining to WT end-of-life have risen in importance in policy and practice. Yet, research on the various factors relating to WT decommissioning is relatively sparse. Moreover, the key assumptions underpinning that prior research (e.g., the lifespan of WTs, characteristics of WTs being decommissioned, and whether the site is repowered with new WTs) have never been empirically tested across a large set of decommissioned WTs. Leveraging a uniquely comprehensive and spatially explicit dataset of decommissioned WTs in the United States, this research analyzes spatial, technological, and temporal trends in WT decommissioning and develops a novel predictive model for WT decommissioning. Our analysis pinpoints more than 12,400 WTs that have been fully decommissioned in the United States., the majority of which have been relatively old (> 30 years) and small (< 200 kW). While a WT's age alone is a good predictor of the likelihood of decommissioning, other factors such as the size of the WT and recent performance are also important and significant predictors. Most sites where decommissioning has occurred have seen subsequent repowering, with repowered plants featuring substantially fewer WTs (−86 on average) and higher rated plant capacity (+62 MW on average). Many existing WTs in the U.S. are approaching the end of their expected life with roughly 7500 being 20 or more years old. Findings can help policymakers and stakeholders begin preparing for this potential wave of future decommissioning and repowering.

Decommissioning / End-of-life↗
DOE OSTI2021

Persistent, “Mysterious” Seismoacoustic Signals Reported in Oklahoma State during 2019

Here, we report on the source of seismoacoustic pulses that were observed across the state of Oklahoma (OK) during summer of 2019, and the subject of national media coverage and speculation. Seismic network data collected across four U.S. states and interviews with witnesses to the pulse’s effect on residential structures demonstrate that they were triggered by routine ammunition disposal operations conducted by McAlester Army Ammunition Plant (McAAP). During these operations, conventional explosives destroy obsolete munitions stored in pits through a controlled sequence of electronically timed shots that occur over tens of minutes. Despite noise-abatement efforts that reduce coupling of acoustic energy with air, some lower frequency, subaudible (infrasonic) sound radiates from these shots as discrete pulses. We use nine months of blast log documents, seismic network records, analyst picks, and physical modeling to demonstrate that seismic stations as far as 640 km from McAAP sample these pulses, which record seasonal patterns in stratospheric and tropospheric winds, as well as the dynamic formation of waveguides and shadow zones. Digital short-term average to long-term average detectors that we augment with dynamic thresholds and time-binning operations identify these pulses with a fair probability, when compared with visual observations. Our analyses thereby provide estimates of observation rates for both partial and full sequences of these pulses, as well as single shots. We suggest that disposal operations can exploit existing, composite seismic networks to predict where residents are likely to witness blasting. Crucially, our data also show that dense seismic networks can record multiscale atmospheric processes in the absence of infrasound arrays.

58 GEOSCIENCES↗
NASA NTRS1986

Electrical power systems for Mars

Electrical power system options for Mars Manned Modules and Mars Surface Bases were evaluated for both near-term and advanced performance potential. The power system options investigated for the Mission Modules include photovoltaics, solar thermal, nuclear reactor, and isotope power systems. Options discussed for Mars Bases include the above options with the addition of a brief discussion of open loop energy conversion of Mars resources, including utilization of wind, subsurface thermal gradients, and super oxides. Electrical power requirements for Mission Modules were estimated for three basic approaches: as a function of crew size; as a function of electric propulsion; and as a function of transmission of power from an orbiter to the surface of Mars via laser or radio frequency. Mars Base power requirements were assumed to be determined by production facilities that make resources available for follow-on missions leading to the establishment of a permanently manned Base. Requirements include the production of buffer gas and propellant production plants.

Giudici, Robert J.↗
NASA NTRS1990

Remote sensing science for the Nineties; Proceedings of IGARSS '90 - 10th Annual International Geoscience and Remote Sensing Symposium, University of Maryland, College Park, May 20-24, 1990. Vols. 1, 2, & 3

Various papers on remote sensing (RS) for the nineties are presented. The general topics addressed include: subsurface methods, radar scattering, oceanography, microwave models, atmospheric correction, passive microwave systems, RS in tropical forests, moderate resolution land analysis, SAR geometry and SNR improvement, image analysis, inversion and signal processing for geoscience, surface scattering, rain measurements, sensor calibration, wind measurements, terrestrial ecology, agriculture, geometric registration, subsurface sediment geology, radar modulation mechanisms, radar ocean scattering, SAR calibration, airborne radar systems, water vapor retrieval, forest ecosystem dynamics, land analysis, multisensor data fusion. Also considered are: geologic RS, RS sensor optical measurements, RS of snow, temperature retrieval, vegetation structure, global change, artificial intelligence, SAR processing techniques, geologic RS field experiment, stochastic modeling, topography and Digital Elevation model, SAR ocean waves, spaceborne lidar and optical, sea ice field measurements, millimeter waves, advanced spectroscopy, spatial analysis and data compression, SAR polarimetry techniques. Also discussed are: plant canopy modeling, optical RS techniques, optical and IR oceanography, soil moisture, sea ice back scattering, lightning cloud measurements, spatial textural analysis, SAR systems and techniques, active microwave sensing, lidar and optical, radar scatterometry, RS of estuaries, vegetation modeling, RS systems, EOS/SAR Alaska, applications for developing countries, SAR speckle and texture.

Source record↗
NASA NTRS1987

Heat transfer to and from vegetated surfaces - An analytical method for the bulk exchange coefficients

The semianalytical model outlined in a previous study (Massman, 1987) to describe momentum exchange between the atmosphere and vegetated surfaces is extended to include the exchange of heat. The methods employed are based on one-dimensional turbulent diffusivities, and use analytical solutions to the steady-state diffusion equation. The model is used to assess the influence that the canopy foliage structure and density, the wind profile structure within the canopy, and the shelter factor can have upon the inverse surface Stanton number (kB exp -1), as well as to explore the consequences of introducing a scalar displacement height which can be different from the momentum displacement height. In general, the triangular foliage area density function gives results which agree more closely with observations than that for constant foliage area density. The intended application of this work is for parameterizing the bulk aerodynamic resistances for heat and momentum exchange for use within large-scale models of plant-atmosphere exchanges.

Massman, William J.↗
NASA NTRS2012

Toward Lower Organic Environments in Astromaterial Sample Curation for Diverse Collections

Great interest was taken during the frenzied pace of the Apollo lunar sample return to achieve and monitor organic cleanliness. Yet, the first mission resulted in higher organic contamination to samples than desired. But improvements were accomplished by Apollo 12 [1]. Quarantine complicated the goal of achieving organic cleanliness by requiring negative pressure glovebox containment environments, proximity of animal, plant and microbial organic sources, and use of organic sterilants in protocols. A special low organic laboratory was set up at University of California Berkeley (UCB) to cleanly subdivide a subset of samples [2, 3, 4]. Nevertheless, the basic approach of handling rocks and regolith inside of a positive pressure stainless steel glovebox and restrict-ing the tool and container materials allowed in the gloveboxes was established by the last Apollo sample re-turn. In the last 40 years, the collections have grown to encompass Antarctic meteorites, Cosmic Dust, Genesis solar wind, Stardust comet grains and Hayabusa asteroid grains. Each of these collections have unique curation requirements for organic contamination monitor-ing and control. Here is described some changes allowed by improved technology or driven by changes in environmental regulations and economy, concluding with comments on organic witness wafers. Future sample return missions (OSIRIS-Rex; Mars; comets) will require extremely low levels of organic contamination in spacecraft collection and thus similarly low levels in curation. JSC Curation is undertaking a program to document organic baseline levels in current operations and devise ways to reduce those levels.

Allton, J. H.↗
NASA NTRS1994

Multirate flutter suppression system design for the Benchmark Active Controls Technology Wing

To study the effectiveness of various control system design methodologies, the NASA Langley Research Center initiated the Benchmark Active Controls Project. In this project, the various methodologies will be applied to design a flutter suppression system for the Benchmark Active Controls Technology (BACT) Wing (also called the PAPA wing). Eventually, the designs will be implemented in hardware and tested on the BACT wing in a wind tunnel. This report describes a project at the University of Washington to design a multirate flutter suppression system for the BACT wing. The objective of the project was two fold. First, to develop a methodology for designing robust multirate compensators, and second, to demonstrate the methodology by applying it to the design of a multirate flutter suppression system for the BACT wing. The contributions of this project are (1) development of an algorithm for synthesizing robust low order multirate control laws (the algorithm is capable of synthesizing a single compensator which stabilizes both the nominal plant and multiple plant perturbations; (2) development of a multirate design methodology, and supporting software, for modeling, analyzing and synthesizing multirate compensators; and (3) design of a multirate flutter suppression system for NASA's BACT wing which satisfies the specified design criteria. This report describes each of these contributions in detail. Section 2.0 discusses our design methodology. Section 3.0 details the results of our multirate flutter suppression system design for the BACT wing. Finally, Section 4.0 presents our conclusions and suggestions for future research. The body of the report focuses primarily on the results. The associated theoretical background appears in the three technical papers that are included as Attachments 1-3. Attachment 4 is a user's manual for the software that is key to our design methodology.

Berg, Martin C.↗
NASA NTRS1994

Results of ozone measurements in Northern Germany: A case study

At most of the German ozone recording stations which have records over a sufficiently long period, the results of the summer months of 1989 showed the highest values since the beginning of the measurements. One of the reasons for this phenomenon was the high duration of sunshine in that summer; for example, in Potsdam near Berlin in May 1989 the sunshine duration was the highest in May since the beginning of the records in 1893. For that reason we selected this summer for a case study. The basis for the study was mainly the ozone measuring stations of the network of Lower Saxony and the Federal Office of Environment (Umweltbundesamt). The results of these summer measurements point to intense sources of ozone, probably in form of gaseous precursors, in the Middle German industrial areas near Leipzig and Halle and in Northwestern Czechoslovakia, with coal-mining, chemical and petrochemical industries, coking plants and others. The maps of average ozone concentrations, number or days with high ozone maxima, ozone-windroses of the stations, etc., suggest that these areas could be a main source of precursors and of photochemical ozone production in summer smog episodes in Central Europe. Stations on the North Sea coast, at which early ozone measurements were made by our institute in 1973/74 are compared with similarly located stations of the Lower Saxon network in 1989 and the results show a reversal of the ozone-windroses. In 1973/74, the highest ozone concentrations were correlated with wind directions from the sea while in 1989 these concentrations were correlated with directions from the continent. In the recent years, photochemical ozone production on the continent is probably predominant, while in former years the higher ozone content of the maritime subpolar air masses has been explained by stratospheric-tropospheric exchange.

Schmidt, Manfred↗
DOE OSTI2023

Hybrid Energy System to H2 to Green Steel/Ammonia

Green hydrogen is a vital pathway to decarbonize industrial sectors responsible for the largest portion of greenhouse gas emissions, including ammonia/fertilizer and steel. It takes approximately a GW-scale renewables hybrid-H2 system to fully convert one average U.S. steel plant to a green steel plant, with an annual production capacity of 100 million metric tons per year. The optimized cost-effective operation of renewables-H2 plants are highly dependent on location and the specific end use designs. This project focused on the analysis of GW-scale off-grid, tightly-coupled, co-located systems to reduce overall cost compared with steam methane reform with and without carbon capture and grid connected systems (see Figure 1).

ammonia↗
DOE OSTI2020

Radiation-Induced Catalysis of Chemical Reactions

Nuclear energy is a process which achieves zero-carbon energy and heat generation that can provide a consistent electricity load to supply the grid when renewables are not available. However, on a cost per kilowatt-hour comparison, nuclear energy is more expensive than many of the renewable energy generation technologies such as wind and solar. In order to increase the economic viability of next generation nuclear reactors for energy production, generation of a secondary product such as a chemical feedstock would increase the economic viability of nuclear energy, particularly for new installations of next-generation nuclear reactors for power production. Currently, commercial nuclear reactors are primarily used for their heat to generate steam for electricity production. There is a large amount of unused energy in the form of photon and neutron radiation that could be exploited to drive chemical processes to produce feedstock materials as a secondary product of a nuclear plant. Chemical processing with radiation is not a new concept. In fact, gamma radiation is an excellent source of high energy photons to drive photochemical reactions. Dow chemical produced commercial quantities of ethyl bromide using gamma irradiation from a 60 Co source in the 1960s and 1970s because it was the most cost-effective means of production to meet the demand.5, 6 Due to the potential economic advantages, there is a new emphasis on studying feedstock production which can be enhanced by excess gamma and neutron radiation, particularly if the reaction could be monitored in real-time which is advantageous for process optimization. A model system of lignocellulose degradation under γ- radiation was chosen for this study while following the degradation products with Raman spectroscopy in real-time.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2024

Integrated Turbine Component Cooling Designs Facilitated by Additive Manufacturing and Optimization

This research program involved the development of improved gas turbine cooling by optimizing the combined internal and film cooling configurations used for turbine blades and vanes. Improved cooling of turbine airfoils allows the gas turbines to be operated at higher temperatures which improves efficiency for gas turbine-based power generation. This also facilitates operation with hydrogen-based fuels which inherently generate higher operating temperatures. Designs of the new cooling configurations were based on the added geometric flexibility that is available when using metal additive manufacturing techniques. When making these designs, adjustments were made to account for imperfections occurring in the metal additive manufacturing process. New designs for film cooling holes were developed using computational adjoint gradient optimization techniques which generated a unique film cooling hole with 70% greater film cooling effectiveness compared to conventional shaped film cooling holes. A major factor in improving the film cooling effectiveness were small external protrusions on either side of the new hole which generated vortices that pushed coolant towards the surface and increased the lateral spreading of the coolant. Our studies also included optimization of film cooling holes that can be built with conventional manufacturing techniques and optimizing the internal coolant channels that supply coolant to the film cooling holes. Various internal coolant channel shapes were investigated and designs that maximized the cooling of the airfoil while minimizing pressure losses in the channel flows were identified. Testing and verification of the performance of the final configurations was done with a transonic wind tunnel facility which allowed testing at engine realistic high velocities. Final testing of the combined internal and film cooling configurations was done by incorporating the configurations in Penn State’s National Experimental Turbine (NExT) vane. These tests confirmed the enhanced overall cooling effectiveness provided by the new cooling configuration designs.

03 NATURAL GAS↗
DOE OSTI2024

Analyzing the upscaling potential and geospatial siting of calcination-free calcium hydroxide production in the United States

This study evaluates the techno-economic feasibility and the embodied carbon dioxide intensity (eCI) of a novel process for producing nominally pure (>95 mass %) calcium hydroxide without the need for the thermal calcination of limestone. The process relies on the aqueous extraction of calcium from alkaline industrial wastes following which portlandite (Ca(OH) 2 : CH, a.k.a. slaked lime or hydrated lime) is precipitated by application of a waste-heat based thermal swing. This approach takes advantage of the temperature dependent solubility of CH at ambient pressure. We evaluated the feasibility of implementing this process in the U.S. based on the geospatial availability of waste heat and slags as a Ca-source. For the base case, the cost of production of “Low-Temperature Portlandite (LTP)” is 2-to-3 times that of traditional portlandite (~$180/tonne). The main driver of cost is the electricity demand for reverse osmosis (RO) which is used to concentrate Ca-ions in solution, and the costs of membrane replacement. Our sensitivity analysis showed that parity with the cost of production of traditional portlandite is readily achievable by selecting membranes with better durability (i.e., better pH resistance) and flux (i.e., higher permeability) without sacrificing selectivity. Significantly, LTP features an eCI that is between 40%- and - 80 % lower than its traditional counterpart when electricity is sourced from natural gas combustion or wind power, respectively. Finally, our geospatial analysis reveals that there are three areas in the U.S. with the potential for implementation of industrial-scale facilities that could produce at least 50 tonnes of pure Ca(OH) 2 per day, while achieving a production cost of ~$270 per tonne of Ca(OH) 2 , owing to the proximity between slag feedstocks and waste heat sources.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2023

Hydrogen Production Cost with Alkaline Electrolysis

Rigorous stakeholder-vetted techno-economic analysis was performed to assess the cost of hydrogen (H 2 ) produced using state-of-the-art Liquid Alkaline (LA) electrolysis. Projected high-volume, untaxed levelized cost of hydrogen (LCOH) range from 2020US $\$ 1.84$ to $\$ 2.88$/kg-H 2 depending on technology year, process design, and electrolyzer project scale, assuming an electricity price of $\$ 0.03$/kWh. The total installed capital cost for a LA electrolysis plant was estimated from bottom-up stack and installed cost models that account for purchased equipment, installation costs, site preparation, and general overhead costs. For this study, the LA electrolysis plant is assumed to be a stick-built, greenfield project developed by an EPC firm with electrolysis stacks purchased directly from an electrolysis stack manufacturer. The price of the electrolysis stacks is based on a bottom-up cost assessment with business markup for the electrolysis company fabricator. Methods from the Hydrogen Analysis (H 2 A) production model, a peer-reviewed national laboratory-developed discounted cash flow model, were used to calculate the LCOH production in 2020$/kg-H 2 . The baseline electricity price case ($\$ 0.03$/kWh) corresponds to average wholesale electricity prices currently possible in U.S. markets with plentiful wind. Similar low-cost electricity pricing is possible from solar Power Purchase Agreements (PPA) although these prices are typically limited by renewable energy capacity factors.

08 HYDROGEN↗
DOE OSTI2025

TARP Identifying Critical Thresholds for Acute Response of Plants and Ecosystems to Water Stress at Walker Branch Watershed, 2002-2005

This dataset contains data from a manipulative field study aimed at identifying critical thresholds for acute response of plants and ecosystems to water stress (TARP) that took place at Walker Branch Watershed in Oak Ridge, Tennessee from 2002-2005 (2002-06-20 to 2005-12-16). The study used understory tents for the removal of 100% of the growing-season throughfall and stem flow, to provide data on the impact of acute drought on mechanisms responsible for growth and mortality of deciduous forest canopy trees representative of common plant functional types (Liriodendron and Quercus). Through three years of manipulation (2003, 2004 and 2005; pretreatment measurements in 2002) various measures of tree response to surface moisture deficits were recorded including root and leaf traits, plant nonstructural carbohydrates status, hourly sapflow, basal area, and periodic observations of foliar photosynthesis and conductance. Additionally, environmental data such as air and soil temperature, soil water content, and soil matric potential were recorded. This dataset contains data 16 files in comma-separate (*.csv) format. Additional metadata are provided: 16 data dictionaries and a file-level metadata file in comma separate (*.csv) format and a user guide in PDF (*.pdf) format.

basal area↗
DOE OSTI2024

Effect of Heat Treatment on Microstructure and Mechanical Property of 316L Stainless Steel Produced by Laser Powder Bed Fusion

The advanced non-light water reactor designs (Gen IV reactors), including molten salt/ very high temperature/ sodium-cooled and lead-cooled fast reactors, typically operate at higher temperatures and more extreme radiation conditions than light water reactors. An intrinsic part of the deployment and progress of Gen IV reactor designs is selecting the most suitable structural material for a specific application. Additive manufacturing (AM), a fairly new process of making physical, three-dimensional objects from a computer design file, is going to completely change the way of design, build and certify nuclear systems. It offers a range of opportunities to produce complex geometries from existing materials, offers new routes for processing of previously difficult to process materials, allows for design of new high-performance materials, and finally facilitates hybridization of dissimilar materials. This emerging technology has successfully produced cars, wind turbine blade molds and even live cells. It could also open up big opportunities for the nuclear industry to quickly deploy technologies at a fraction of the cost. So far, AM techniques have been preliminarily applied in the field of nuclear reactors, including the classical parts such as the pressure vessel of a small reactor with 508-III steel, the bottom nozzle of a fuel assembly with 304L steel, the fuel cladding with zirconium alloy and the integrated impeller of a pump and the multi-channel valve body with 316L steel [6,7]. The AM applications for operating nuclear reactors started in auxiliary plant components and have slowly migrated to metallic reactors and core components, but many of these are not safety critical components. Although many parts used for nuclear reactors have been fabricated by AM techniques, practical applications in engineering are still a long way off due to the uncertainty factors focused on the processing, material properties, analysis methods and application standards, which feeds the safety and life-cycle of the nuclear reactor. Due to rapid, repeated heating and cooling during production, a high dislocation density was present in the AM material. This microstructure feature is unstable at elevated temperature while high temperature is one of the typical operation environments for nuclear reactors. Thus, it is important to understand the thermal effect on the microstructure of AM material. The objectives of this study are to investigate the effect of heat treatment on the microstructure and mechanical properties of 316L stainless steel produced by laser powder bed fusion additive manufacturing, and to determine an appropriate heat treatment practice that will be applied to the lightweight AM lattice-structured material with the same chemistry. The heat treatment study consisted of annealing the samples at a temperature range of 800 to 1200 oC with a 50 oC increment for different times (1-24 hours), followed by vacuum or air cooling. Microstructural characterization was carried out by Scanning Electron Microscope (SEM). Grain size and crystallographic orientation were investigated by Electron Backscatter Diffraction (EBSD). Vickers hardness tests with a 0.5 kg load were employed to determine the hardness of samples after different heat treatments. After heat treatment, the random crystallographic orientation was preserved, and the volume fraction of high-angle grain boundaries (grain boundary misorientation =15 oC) remained the same. The dislocation density decreased with annealing temperature due to recovery. The fine subgrain structures in the as-printed specimen were quite stable up to 1200 oC. Minimal recrystallization was observed up to 1200 oC. Recrystallization initiated only after 8.5 hours at 1200 oC. The SEM images did not show obvious dependence of microstructure on cooling rate. The hardness of the specimens decreased with increasing annealing temperature as a result of the decrease in dislocation density. It is interesting to note that the AM material showed very similar hardness to the wrought material when annealing at similar temperature, although the microstructures are very different. Annealing at 1050 oC for 1 hour followed by air cooling was selected as the heat treatment procedure for the lattice designed lightweight AM 316L material.

36 MATERIALS SCIENCE↗