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At least 775 records · Page 43
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

A new magnesium sheet alloy with high tensile properties and room-temperature formability

Lightweight sheet alloys with superior mechanical performance such as high strength, ductility and formability at room temperature (RT) are desirable for high volume automotive applications. However, ductility or formability of metallic alloys at RT are generally inversely related to strength, thereby making it difficult to optimize all three simultaneously. Here we design a new magnesium sheet alloy-ZAXME11100 (Mg-1.0Zn-1.0Al-0.5Ca-0.4Mn-0.2Ce, wt. pct.) via CALPHAD (CALculation of PHAse Diagram) modeling and experimental validation. This new sheet alloy offers an excellent RT formability with a high Index Erichsen (I.E.) value of 7.8 mm in a solution-treated condition (T4), due to its weak and split basal texture and fine grain structure. The new ZAXME 11100 alloy also shows a rapid age-hardening response during post-forming artificial aging treatment at 210 °C for 1hour (T6), resulting in a significant increase of yield strength from 159 MPa (T4) to 270 MPa (T6). The excellent combination of T4 ductility (31%), T4 formability (7.8 mm) and T6 yield strength (270 MPa) in this new magnesium alloy is comparable to that of common 6xxx series aluminum sheet alloys. Thus, this new magnesium sheet alloy is highly attractive for sheet applications in automotive and other industries.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Forming mechanism of equilibrium and non-equilibrium metallurgical phases in dissimilar aluminum/steel (Al–Fe) joints

Abstract Forming metallurgical phases has a critical impact on the performance of dissimilar materials joints. Here, we shed light on the forming mechanism of equilibrium and non-equilibrium intermetallic compounds (IMCs) in dissimilar aluminum/steel joints with respect to processing history (e.g., the pressure and temperature profiles) and chemical composition, where the knowledge of free energy and atomic diffusion in the Al–Fe system was taken from first-principles phonon calculations and data available in the literature. We found that the metastable and ductile (judged by the presently predicted elastic constants) Al 6 Fe is a pressure ( P ) favored IMC observed in processes involving high pressures. The MoSi 2 -type Al 2 Fe is brittle and a strong P -favored IMC observed at high pressures. The stable, brittle η-Al 5 Fe 2 is the most observed IMC (followed by θ-Al 13 Fe 4 ) in almost all processes, such as fusion/solid-state welding and additive manufacturing (AM), since η-Al 5 Fe 2 is temperature-favored, possessing high thermodynamic driving force of formation and the fastest atomic diffusivity among all Al–Fe IMCs. Notably, the ductile AlFe 3 , the less ductile AlFe, and most of the other IMCs can be formed during AM, making AM a superior process to achieve desired IMCs in dissimilar materials. In addition, the unknown configurations of Al 2 Fe and Al 5 Fe 2 were also examined by machine learning based datamining together with first-principles verifications and structure predictions. All the IMCs that are not P- favored can be identified using the conventional equilibrium phase diagram and the Scheil-Gulliver non-equilibrium simulations.

36 MATERIALS SCIENCE↗
DOE OSTI2012

Constitutive Law and Flow Mechanism in Diamond Deformation

Constitutive laws and crystal plasticity in diamond deformation have been the subjects of substantial interest since synthetic diamond was made in 1950's. To date, however, little is known quantitatively regarding its brittle-ductile properties and yield strength at high temperatures. In this paper, we report, for the first time, the strain-stress constitutive relations and experimental demonstration of deformation mechanisms under confined high pressure. The deformation at room temperature is essentially brittle, cataclastic, and mostly accommodated by fracturing on {111} plane with no plastic yielding at uniaxial strains up to 15%. At elevated temperatures of 1000°C and 1200°C diamond crystals exhibit significant ductile flow with corresponding yield strength of 7.9 and 6.3 GPa, indicating that diamond starts to weaken when temperature is over 1000°C. Finally, at high temperature the plastic deformation and ductile flow is meditated by the <110>{111} dislocation glide and a very active {111} micro-twinning.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Laser shock peening on Zr-based bulk metallic glass and its effect on plasticity: Experiment and modeling

The Zr-based bulk metallic glasses (BMGs) are a new family of attractive materials with good glass-forming ability and excellent mechanical properties, such as high strength and excellent wear resistance, which make them candidates for structural and biomedical materials. Although the mechanical behavior of BMGs has been widely investigated, their deformation mechanisms are still poorly understood. In particular, their poor ductility significantly impedes their industrial application. In the present work, we show that the ductility of Zr-based BMGs with nearly zero plasticity is improved by a laser shock peening technique. Moreover, we map the distribution of laser-induced residual stresses via the micro-slot cutting method, and then predict them using a three dimensional finite-element method coupled with a confined plasma model. Reasonable agreement is achieved between the experimental and modeling results. The analysis of serrated flow reveals plentiful and useful information of the underlying deformation process. As a result, our work provides an easy and effective way to extend the ductility of intrinsically-brittle BMGs, opening up wider applications of these materials.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Super-stretchable metallic interconnects on polymer with a linear strain of up to 100%

Metal interconnects in flexible and wearable devices are heterogeneous metal-polymer systems that are expected to sustain large deformation without failure. The principal strategy to make strain tolerant interconnect lines on flexible substrates has comprised of creating serpentine structures of metal films with either in-plane or out-of-plane waves, using porous substrates, or using highly ductile materials such as gold. The wavy and helical serpentine patterns preclude high-density packing of interconnect lines on devices, while ductile materials such as Au are cost prohibitive for real world applications. Ductile copper films can be stretched if bonded to the substrate, but show high level of cracking beyond few tens of % strain. In this paper, we demonstrate a material system consisting of Indium metal film over an elastomer (PDMS) with a discontinuous Cr layer such that the metal interconnect can be stretched to extremely high linear strain (up to 100%) without any visible cracks. Such linear strain in metal interconnects exceeds that reported in literature and is obtained without the use of any geometrical manipulations or porous substrates. Systematic experimentation is carried out to explain the mechanisms that allow the Indium film to sustain the high strain level without failure. The islands forming the discontinuous Cr layer are shown to move apart from each other during stretching without delamination, providing strong adhesion to the Indium film while accommodating the large strain in the system. The Indium film is shown to form surface wrinkles upon release from the large strain, confirming its strong adhesion to PDMS. A model is proposed based upon the observations that can explain the high level of stretch-ability of the Indium metal film over the PDMS substrate.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2024

Active doping controls the mode of failure in dense colloidal gels

Mechanical properties of disordered materials are governed by their underlying free energy landscape. In contrast to external fields, embedding a small fraction of active particles within a disordered material generates nonequilibrium internal fields, which can help to circumvent kinetic barriers and modulate the free energy landscape. In this work, we investigate through computer simulations how the activity of active particles alters the mechanical response of deeply annealed polydisperse colloidal gels. We show that the “swim force” generated by the embedded active particles is responsible for determining the mode of mechanical failure, i.e., brittle vs. ductile. We find, and theoretically justify, that at a critical swim force the mechanical properties of the gel decrease abruptly, signaling a change in the mode of mechanical failure. The weakening of the elastic modulus above the critical swim force results from the change in gel porosity and distribution of attractive forces among gel particles, while below the critical swim force, the ductility enhancement is caused by an increase of gel structural disorder. Above the critical swim force, the gel develops a pronounced heterogeneous structure characterized by multiple pore spaces, and the mechanical response is controlled by dynamical heterogeneities. We contrast these results with those of a simulated monodisperse gel that exhibits a nonmonotonic trend of ductility modulation with increasing swim force, revealing a complex interplay between the gel energy landscape and embedded activity.

Zhou, Tingtao (ORCID:000000021766719X)↗
DOE OSTI2025

Thermal-Fluid and Thermal-Structural Response of the T-Tube Modular Divertor to Spatiotemporally Varying Heat Loads

Tungsten (W) is the leading candidate for divertor target plates because of its high melting point (>3000°C), thermal conductivity, and ultimate tensile stress. While W and its alloys are the only solid materials that can survive the high heat fluxes incident on the divertor, W’s low-ductility high ductile-to-brittle transition temperature of ~600°C and relatively low recrystallization temperature (RT) of ~1300°C pose structural (among other) challenges. The objective of this work is to estimate the thermal-fluid and thermal-structural performance of the helium (He)-cooled T-tube divertor, which was originally developed by the Advanced Reactor Innovation and Evaluation Study (ARIES) using numerical simulations. Here, predictions of temperature distributions across the plasma-facing structural component and surface pressures from computational fluid dynamics simulations are used to determine stress distributions using commercial structural finite element modeling software over a range of fusion-relevant conditions. The maximum allowable incident heat fluxes are determined based on the temperature limits imposed by the ITER elastic Structural Design Criteria for In-vessel Components (SDC-IC) and the maximum RT over a range of He mass flow rates and presented in the form of performance design charts. Our recent work found that thermal- structural criteria accounting for the low ductility of W in a finger-type modular divertor constrain the maximum incident heat fluxes to values well below the ITER specifications, and those based on considering only the RT demonstrate that integrated thermal-fluid and elastic structural performance evaluation are required for accurate assessment of divertor performance. This novel analysis of the T-tube considers how nonuniform and transient incident heat fluxes affect its thermal-fluid and thermal-structural performance, as well as the effect of volumetric heating, which can be as great as 27% of the power incident on the divertor surface. The W tile of the T-tube, with its relatively large plasma-facing area of ~15 cm 2 , will likely experience significant spatial variations in incident heat flux. This work therefore assesses whether steady-state incident heat flux profiles with a peak of 10 MW/m 2 and maximum heat flux gradients of 200 MW/m 2 per m exceed the structural limits imposed by the ITER elastic SDC-IC and the maximum RT over a range of fusion-relevant conditions. The effect of transient heat fluxes typical of plasma detachment and reattachment from the target plate due, for example, to gas injection are also evaluated

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2013

Phase stability and elastic properties of Cr-V alloys

V is the only element in the periodic table that forms a complete solid solution with Cr and thus is particularly important in alloying strategy to ductilize Cr. This study combines first-principles density functional theory calculations and experiments to investigate the phase stability and elastic properties of Cr–V binary alloys. The cluster expansion study reveals the formation of various ordered compounds at low temperatures that were not previously known. These compounds become unstable due to the configurational entropy of bcc solid solution as the temperature is increased. The elastic constants of ordered and disordered compounds are calculated at both T = 0 K and finite temperatures. The overall trends in elastic properties are in agreement with measurements using the resonant ultrasound spectroscopy method. The calculations predict that addition of V to Cr decreases both the bulk modulus and the shear modulus, and enhances the Poisson’s ratio, in agreement with experiments. Decrease in the bulk modulus is correlated to decrease in the valence electron density and increase in the lattice constant. An enhanced Poisson’s ratio for bcc Cr–V alloys (compared to pure Cr) is associated with an increased density of states at the Fermi level. Furthermore, the difference charge density in the bonding region in the (110) slip plane is highest for pure Cr and decreases gradually as V is added. The present calculation also predicts a negative Cauchy pressure for pure Cr, and it becomes positive upon alloying with V. The intrinsic ductilizing effect from V may contribute, at least partially, to the experimentally observed ductilizing phenomenon in the literature.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Material and component developments for the DEMO divertor using fibre reinforcement and additive manufacturing

Within the research along the European Fusion Roadmap, water-cooled divertor PFCs are foreseen in the design of a first fusion demonstration power plant (DEMO) in order to provide reliable heat removal capability. In the frame of this concerted attempt, the Max Planck Institute for Plasma Physics is concentrating on the development and testing of composite materials based on tungsten (W, preferred armour material) and copper (Cu, preferred heat sink material). W fibres (W f ) as monofilaments and yarns as reinforcement play a central role in these investigations due to their extraordinary properties concerning ductility already at room temperature and high tensile strength. Recent investigations on the impact of radiation damage suggest that the fibres retain their ductility upon irradiation. W reinforced with W fibres (W f /W) allows to overcome the intrinsic brittleness of W. Quantitative mechanical fracture tests of W f /W confirm the basic mechanisms of fibre reinforcement and the increased resistance to mechanical fatigue. The good wettability of W with liquid Cu and the absence of any metallurgical solubility make up an ideal material pairing for composite production. W fibre-reinforced Cu (W f /Cu) cooling tubes provide a rather high thermal conductivity (> 250 W mK -1 ) and at least twice the strength of CuCrZr in hoop direction in the temperature range up to at least 500 °C. Very recent neutron irradiation experiments confirm the sustainment of ductility of the W f /Cu composite. Numerical simulations suggest that thermal stresses in W-Cu PFCs could be strongly reduced by tailoring the local W and Cu volume fraction. This 'freely' distributed material composition can be achieved by means of additively manufactured W skeletons consecutively infiltrated by Cu. Investigations with W preforms produced by Laser Beam Powder Bed Fusion and infiltrated by Cu demonstrate the feasibility of this approach while testing of specifically prepared specimen is ongoing.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2026

Effect of deposition rate on microstructure and mechanical properties of 17-4 PH stainless steel fabricated by laser engineered net shaping

Laser engineered net shaping (LENS) is an additive manufacturing technique for fabricating and repairing metallic components. However, the relationships between its process parameters and the resulting mechanical properties of alloys such as 17-4 precipitation-hardening (PH) stainless steel require further investigation to enable reliable application. This study examines the specific effect of LENS deposition rate on the microstructure and mechanical properties of 17-4 PH stainless steel. Specimens were fabricated at two different deposition rates (8.47 and 9.31 mm s−1), subjected to subsequent solution and H900 aging treatment, and then evaluated via tensile testing, hardness measurements, and microscopy. A higher deposition rate results in a finer grain structure but increased porosity, leading to greater ultimate tensile strength (∼1294 MPa) yet lower ductility (strain at failure ∼5.8%) compared to the slower deposition rate (∼1266 MPa, ∼9.0% strain). Hardness follows the same trend as tensile strength. Tensile fracture surfaces for both conditions exhibited a mixed mode of ductile dimples and brittle quasi-cleavage regions, with chromium/silicon oxide particles identified within dimples. Complementary finite element modeling indicates that small void fractions primarily reduce ductility by enhancing localized plasticity, with only a marginal decrease in tensile strength. These integrated experimental and numerical results elucidate the mechanical properties linked to deposition rate, providing insight into tailoring LENS processes to achieve desired properties of 17-4 PH stainless steel.

17-4 PH stainlesssteel↗
DOE OSTI2021

Effect of hydrogen on tensile properties of 304L stainless steel at cryogenic temperatures

Safe and efficient hydrogen storage and distribution are key attributes to realizing hydrogen as an alternative energy carrier. To this end, cryogenic liquid and cryo-compressed gaseous hydrogen are considered high energy density alternatives to ambient temperature gas. However, these alternatives have significant material demands to overcome extreme temperature (20 K) and pressure (700 bar) as well as hydrogen effects. Austenitic stainless steels are widely used for cryogenic pressure vessels owing to relatively high ductility even at 4 K. However, the influence of hydrogen on mechanical properties at cryogenic temperatures has rarely been studied. In this study, the tensile properties of 304L austenitic stainless steel with internal hydrogen were evaluated at 20 K, 77 K, and 113 K. Test specimens were saturated with internal hydrogen to concentration of 140 wtppm in a high pressure environment at elevated temperature, a process called thermal precharging. While lower temperature in known to increase strength properties and reduced elongation at fracture, the presence of internal hydrogen increased both strength and elongation at fracture, but reduced ductility. Magnetic evaluation of the uniformly strained region of the test specimens suggest that hydrogen mitigates the strain-induced transformation to a’-martensite. Brittle fracture features and secondary cracking indicative of hydrogen embrittlement were observed on the fracture surfaces of hydrogen-precharged specimens, which is consistent with the loss of ductility.

Merkel, Daniel R.↗
DOE OSTI2022

Exceptional fracture toughness of CrCoNi-based medium- and high-entropy alloys at 20 kelvin

Medium- and high-entropy alloys based on the CrCoNi-system have been shown to display outstanding strength, tensile ductility and fracture toughness (damage-tolerance properties), especially at cryogenic temperatures. Here we examine the J Ic and (back-calculated) K JIc fracture toughness values of the face-centered cubic, equiatomic CrCoNi and CrMnFeCoNi alloys at 20 K. At flow stress values of ~1.5 GPa, crack-initiation K JIc toughnesses were found to be exceptionally high, respectively 235 and 415 MPa√m for CrMnFeCoNi and CrCoNi, with the latter displaying a crack-growth toughness K ss exceeding 540 MPa√m after 2.25 mm of stable cracking, which to our knowledge is the highest such value ever reported. Characterization of the crack-tip regions in CrCoNi by scanning electron and transmission electron microscopy reveal deformation structures at 20 K that are quite distinct from those at higher temperatures and involve heterogeneous nucleation, but restricted growth, of stacking faults and fine nanotwins, together with transformation to the hexagonal closed-packed phase. The coherent interfaces of these features can promote both the arrest and transmission of dislocations to generate respectively strength and ductility which strongly contributes to sustained strain hardening. Indeed, we believe that these nominally single-phase, concentrated solid-solution alloys develop their fracture resistance through a progressive synergy of deformation mechanisms, including dislocation glide, stacking-fault formation, nano-twinning and eventually in situ phase transformation, all of which serve to extend continuous strain hardening which simultaneously elevates strength and ductility (by delaying plastic instability), leading to truly exceptional resistance to fracture.

36 MATERIALS SCIENCE↗
DOE OSTI2012

Bulk nanostructured austenitic stainless steels with enhanced radiation tolerance

The objective of this project is to increase radiation tolerance in austenitic steels through optimization of grain size and grain boundary (GB) characteristics. The focus will be on nanocrystalline austenitic Fe-Cr-Ni alloys with an fcc crystal structure. The long-term goal is to design and develop bulk nanostructured austenitic steels with enhanced void swelling resistance and substantial ductility, and to enhance their creep resistance at elevated temperatures via GB engineering. The combination of grain refinement and grain boundary engineering approaches allows us to tailor the material strength, ductility, and resistance to swelling by 1) changing the sink strength for point defects, 2) by increasing the nucleation barriers for bubble formation at GBs, and 3) by changing the precipitate distributions at boundaries. Compared to ferritic/martensitic steels, austenitic stainless steels (SS) possess good creep and fatigue resistance at elevated temperatures, and better toughness at low temperature. However, a major disadvantage of austenitic SS is that they are vulnerable to significant void swelling in nuclear reactors, especially at the temperatures and doses anticipated in the Advanced Burner Reactor. The lack of resistance to void swelling in austenitic alloys led to the switch to ferritic/martensitic steels as the preferred material for the fast reactor cladding application. Recently a type of austenitic stainless steel, HT-UPS, was developed at ORNL, and is expected to show enhanced void swelling resistance through the trapping of point defects at nanometer-sized carbides. Reducing the grain size and increasing the fraction of low energy grain boundaries should reduce the available radiation-produced point defects (due to the increased sink area of the grain boundaries), should make bubble nucleation at the boundaries less likely (by reducing the fraction of high-energy boundaries), and improve the strength and ductility under radiation by producing a higher density of nanometer sized carbides on the boundaries. This project will focus on void swelling but advances in processing of austenitic steels are likely to also improve the radiation response of the mechanical properties.

36 MATERIALS SCIENCE↗
DOE OSTI2012

Energy Saving Melting and Revert Reduction Technology: Aging of Graphitic Cast Irons and Machinability

The objective of this task was to determine whether ductile iron and compacted graphite iron exhibit age strengthening to a statistically significant extent. Further, this effort identified the mechanism by which gray iron age strengthens and the mechanism by which age-strengthening improves the machinability of gray cast iron. These results were then used to determine whether age strengthening improves the machinability of ductile iron and compacted graphite iron alloys in order to develop a predictive model of alloy factor effects on age strengthening. The results of this work will lead to reduced section sizes, and corresponding weight and energy savings. Improved machinability will reduce scrap and enhance casting marketability. Technical Conclusions: Age strengthening was demonstrated to occur in gray iron ductile iron and compacted graphite iron. Machinability was demonstrated to be improved by age strengthening when free ferrite was present in the microstructure, but not in a fully pearlitic microstructure. Age strengthening only occurs when there is residual nitrogen in solid solution in the Ferrite, whether the ferrite is free ferrite or the ferrite lamellae within pearlite. Age strengthening can be accelerated by Mn at about 0.5% in excess of the Mn/S balance Estimated energy savings over ten years is 13.05 trillion BTU, based primarily on yield improvement and size reduction of castings for equivalent service. Also it is estimated that the heavy truck end use of lighter castings for equivalent service requirement will result in a diesel fuel energy savings of 131 trillion BTU over ten years.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2011

Report on Thermal Aging Effects on Tensile Properties of Advanced Austenitic Steels

This report provides an update on the evaluation of thermal-aging induced degradation of tensile properties of advanced HT-UPS austenitic stainless steels. The report is the second deliverable (level 3) in FY11 (M3A11AN04030103), under the Work Package A-11AN040301, “Advanced Alloy Testing” performed by Argonne National Laboratory, as part of Advanced Structural Materials Program for the Advanced Reactor Concepts. This work package supports the advanced structural materials development by providing tensile data on aged alloys and a mechanistic model, validated by experiments, with a predictive capability on long-term performance. The scope of work is to evaluate the effect of thermal aging on the tensile properties of advanced alloys such as ferritic-martensitic steels, mod.9Cr-1Mo (G91), G92, and advanced austenitic stainless steel, HT-UPS. The aging experiments have been conducted over a temperature of 550-750°C for various time periods to simulate the microstructural changes in the alloys. In addition, a mechanistic model based on thermodynamics and kinetics has been used to address the changes in microstructure of the alloys as a function of time and temperature, which is developed in the companion work package at ANL. The focus of this project is advanced alloy testing and understanding the effects of long-term thermal aging on the tensile properties. The first deliverable of FY11 reported the tensile testing results of thermally-aged G92 in the normalized and tempered condition (H1 G92), G92 in the cold-rolled condition (H2 G92), and reference alloy, G91 ferritic-martensitic steels. This report summarizes the tensile data of thermally aged HT-UPS austenitic stainless steel. Two heats of HT-UPS have been investigated, i.e., solution-annealed HT-UPS (SA HT-UPS) and hot-rolled HT-UPS (HR HT-UPS). Tensile data have been obtained for SA HT-UPS thermally-aged for up to 18031 h at 550°C and for up to 17595 h at 650°C, as well as for HR HT-UPS thermally aged for up to 6909 h at 550°C, 4293 h at 600°C, and 5407 h at 650°C. Major finding are: (1) the solution-annealed HT-UPS showed continued, moderate increase in strength and decrease in ductility with increasing aging time up to 18034 h at 550°C. Thermal aging at 650°C increased the yield stress and decreased the ultimate tensile strength and drastically reduced the ductility in the SA HT-UPS. For the HR HT-UPS, thermal aging at 550°C for up to 6909 h showed little influence on its tensile behavior. Thermal aging at 600°C for 4293 h increased the strength and decreased the ductility. The 650°C-thermally-aged HR HT-UPS specimens showed very different strengthening, strain hardening, and flow localization behavior. Thermal aging at 650°C increased the yield stress but decreased the ultimate tensile stress for the HR HT-UPS. (2) Dynamic strain aging (DSA) was observed in both the solution-annealed HT-UPS and the hot-rolled HT-UPS at temperatures between 550-650°C at a strain rate of 0.001 s -1 . Extensive precipitation in the matrix after thermal aging at 600 and 650°C significantly reduced serrated plastic flow observed in the stress-strain curves, i.e. less effect of DSA. Because the DSA phenomenon can have significant influence on tensile, creep strength, and fatigue resistance, and the DSA effects in HT-UPS steels were observed in the temperature range of interest to the SFR applications, the DSA phenomenon in the HT.

Li, Meimei↗
DOE OSTI2013

Technical Letter Report of Slow-Strain-Rate Tensile Tests on Irradiated Stainless Steels in a PWR Environment

Slow-strain-rate tensile (SSRT) tests have been performed on irradiated specimens in a simulated pressurized water reactor (PWR) environment. The samples are miniature tensile specimens of various austenitic stainless steels (SSs) with different thermal-mechanical treatments commonly used for reactor core internal components. Neutron irradiation was carried out in the BOR-60 reactor, a sodium-cooled, fast breeder reactor in Russia, at ~320°C. The damage doses of the specimens are 5, 10, and 48 dpa (displacements per atom). All irradiated materials show significant irradiation hardening and loss of ductility in the SSRT tests. The yield strengths of cold-worked are higher than that of solution-annealed samples at all doses up to 48 dpa. While the irradiation hardening seems to saturate between ~5 and ~10 dpa, the loss of ductility continues to increase above 10 dpa. Strain softening is also observed for all irradiated materials above 5 dpa. Fractographic examinations show that ductile dimple fracture is the dominant morphology for all SSRT tests in the PWR environment. Small areas of transgranular, mixed mode and cleavage fractures are seen on most fracture surfaces in PWR water tests. Intergranular cracking is also observed in 48-dpa Types 316 and 347 SSs. Cracking susceptibility of the tested materials was evaluated with fracture morphology and time to failure. In general, high-doses cold-worked SSs are more susceptible to transgranular cleavage cracking in the PWR environment. Solution-annealed Type 347 SS is susceptible to intergranular cracking at 45 dpa in the PWR environment.

Chen, Y.↗
DOE OSTI2016

2nd Gen FeCrAl ODS Alloy Development For Accident-Tolerant Fuel Cladding

Extensive research at ORNL aims at developing advanced low-Cr high strength FeCrAl alloys for accident tolerant fuel cladding. One task focuses on the fabrication of new low Cr oxide dispersion strengthened (ODS) FeCrAl alloys. The first Fe-12Cr-5Al+Y 2 O 3 (+ ZrO 2 or TiO 2 ) ODS alloys exhibited excellent tensile strength up to 800 C and good oxidation resistance in steam up to 1400 C, but very limited plastic deformation at temperature ranging from room to 800 C. To improve alloy ductility, several fabrication parameters were considered. New Fe-10-12Cr-6Al gas-atomized powders containing 0.15 to 0.5wt% Zr were procured and ball milled for 10h, 20h or 40h with Y2O3. The resulting powder was then extruded at temperature ranging from 900 to 1050 C. Decreasing the ball milling time or increasing the extrusion temperature changed the alloy grain size leading to lower strength but enhanced ductility. Small variations of the Cr, Zr, O and N content did not seem to significantly impact the alloy tensile properties, and, overall, the 2nd gen ODS FeCrAl alloys showed significantly better ductility than the 1st gen alloys. Tube fabrication needed for fuel cladding will require cold or warm working associated with softening heat treatments, work was therefore initiated to assess the effect of these fabrications steps on the alloy microstructure and properties. This report has been submitted as fulfillment of milestone M3FT 16OR020202091 titled, Report on 2nd Gen FeCrAl ODS Alloy Development for the Department of Energy Office of Nuclear Energy, Advanced Fuel Campaign of the Fuel Cycle R&D program.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Large Scale Screening of Low Cost Ferritic Steel Designs For Advanced Ultra Supercritical Boiler Using First Principles Methods

Advanced Ultra Supercritical Boiler (AUSC) requires materials that can operate in corrosive environment at temperature and pressure as high as 760°C (or 1400°F) and 5000psi, respectively, while at the same time maintain good ductility at low temperature. We develop automated simulation software tools to enable fast large scale screening studies of candidate designs. While direct evaluation of creep rupture strength and ductility are currently not feasible, properties such as energy, elastic constants, surface energy, interface energy, and stack fault energy can be used to assess their relative ductility and creeping strength. We implemented software to automate the complex calculations to minimize human inputs in the tedious screening studies which involve model structures generation, settings for first principles calculations, results analysis and reporting. The software developed in the project and library of computed mechanical properties of phases found in ferritic steels, many are complex solid solutions estimated for the first time, will certainly help the development of low cost ferritic steel for AUSC.

36 MATERIALS SCIENCE↗