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At least 829 records · Page 46

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DOE OSTI2020

High Temperature Erosion In Particle Based CSP Systems

Particle based concentrated solar power plants are increasingly being considered as an alternative to molten salts. Although these particle based systems provide the inherent safety and enhanced lifetime from reduced corrosion compared to molten salt systems, they bring in complexities associated with surface erosion from falling particle impact and sliding motion along the surfaces. Past research on particle related erosion has been limited to high velocity applications and doesn’t necessarily coincide with the operating conditions in CSP systems. In our work, we evaluate characterize the rate of erosion for particles and containment materials at 800ºC. Three different types of erosion resulting from a) impact of solid particles on receiver, particle storage, and heat exchanger walls; b) abrasion erosion from particle sliding motion along walls; and c) attrition erosion as the particles breakdown from particle-to-particle contact and particle-to-wall interactions are evaluated and compared across a varied spectrum of particle and containment material spectrum. From the results, It is noted that temperature plays a key role in the rate of erosion experienced by any material. With the increase in temperature, materials become more ductile and are more readily sheared away from particle impinging or sliding motion. Furthermore, the particles themselves have higher susceptibility to breakdown which also lowers particle thermal absorptance and thus efficiency as heat transfer fluid.

14 SOLAR ENERGY↗

DOE OSTI2020

Influence of Process Parameters and Alloy Composition on Crack Mitigation in Selective Laser Melting

Microcracking and residual stresses are key limitations of laser powder bed fusion (LPBF), an additive manufacturing (AM) technique that uses a high power laser to consolidate successive layers of metal powder. For tungsten, these microcracks find their origin in the combination of a ductile-to-brittle transition (DBT) between 200°C and 400°C and high residual stresses. This work utilized in situ high speed video to capture the cracking mechanisms, and combined the experimental results with thermomechanical modeling to unveil correlations between crack network morphology and process parameter-related variables, such as the local temperature and residual stress distributions. Consequently, preheating and alloying with rare earth oxides were adopted as possible crack mitigation strategies, the efficacy of which was tested against the initial fundamental baseline results. Preheating temperatures above 500°C eliminated all cracking, though this threshold is expected to be higher when tungsten powder (higher oxygen content) is introduced. Alloying can serve as an active oxygen getter in the system, but the rare earth oxides in this work were too large to have significant contributions to crack-mitigation.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Multiscale modeling of shear banding in metallic glasses (Final report)

Metallic glasses (MGs) possess remarkably high strength but suffer from minimal tensile ductility due to the formation of catastrophic shear bands. The goal of this research project is to develop an understanding of the microstructures and deformation mechanisms that control shear banding in MGs, which will enable the development of MGs with enhanced plasticity. Two scientific objectives have been pursued. (1) Understand the underlying mechanisms of shear banding phenomena in presence of nanoscale heterogeneities in MGs. (2) Understand the evolution of MG heterogenous structure upon thermomechanical stimuli for plasticity enhancement through controlling and distributing multiple shear bands.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Impact Response of Cold Spray Deposited Materials

Solid-state cold spraying (CS) of metals and respective blends is becoming increasingly attractive compared to conventional high temperature processes due to the unique properties such as increased yield strength, low ductility, and differences in tensile and compressive strengths that result from microstructural features due to the CS process. Here we report the results of plate impact experiments applied to CS deposits of tantalum (Ta), niobium (Nb), and a tantalum- niobium blend (TaNb). These methods allowed for definition of the Hugoniot for each material type and allowed for assessment of the Hugoniot Elastic Limit (HEL). Scanning electron microscopy was used on recovered samples to characterize the fracture mechanism during spallation.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Falling particle impact erosion testing for particle based CSP systems

CSP systems are currently being examined as an effective method for using solar energy to generate electricity. While much of this research has been conducted using molten salt as the heat transfer medium, in recent years, solid particles have been posited as a cheaper and more energy efficient heat transfer medium for use in CSP systems. Many researchers have looked into the effectiveness of solid particles as a heat transfer medium. However, a concern with the use of particles is that the falling particles will impact various components within the CSP system, such as the hopper, the heat exchanger, and the insulating material, resulting in surface erosion and damage. With repeated impacts from falling particles, material from the surfaces under impact is removed. The degree of erosion depends on whether the substrate is made of brittle or ductile material. Furthermore, factors such as particle shape, size, hardness, concentration, impact angle, particle velocity, and substrate hardness will contribute to the erosion process and determine how much and how quickly erosion will takes place in a system. Three types of erosion will be observed simultaneously: impact erosion from particle impact on receiver, particle storage, and heat exchanger walls, abrasion erosion from particle sliding motion along walls, and attrition erosion as the particles breakdown from particle-to-particle contact and particle-to-wall interactions. It is imperative to understand each of these erosions individually for a more comprehensive understanding and prediction of CSP system durability. In this work, we developed an experimental test setup capable of measuring impact erosion at conditions relevant to 1MW CSP plant. Subsequently, Impact erosion measurements were performed for three different candidate substrate materials at low particle velocities using HSP 40/70 ceramic particles.

14 SOLAR ENERGY↗

DOE OSTI2020

Experimental Testing of Particle Erosion and Attrition in CSP Systems

In CSP systems using solid particles for heat transfer, erosion from the falling particles can damage the system components upon impact, and from sliding against the component walls. Furthermore, the resulting attrition of particles can change the thermal performance due to alterations in particle morphology. The research on these issues has been limited to industrial applications, and don’t necessarily coincide with the operating conditions in CSP systems. In this work, we investigated the durability of the particles selected as the heat transfer media, as well as special substrate materials that are of interest as lining materials to the particle storage tanks and hoppers. Three different erosion phenomena were studied: impact, abrasion, and attrition erosion. The low-temperature experiments revealed negligible losses from attrition and abrasion erosion. Although the substrates indicated visible surface damage from impact erosion, the actual material mass loss was small even after a throughput of 500kg of particles 63 days of 1MW CSP plant operation assuming 14 hours per day of operation. Erosion is typically classified as impact, abrasion, or attrition erosion. For example, the CSP systems utilizing solid particles as heat transfer media will likely experience impact erosion on the receiver hopper and heat exchanger walls as the solid particles fall from the reservoir. Additionally, there will be sliding erosion along the receiver walls as particles move through the hopper, and lastly, there will also be attrition erosion as the particles rub against each other. The extent of erosion depends on many factors including but not limited to particle shape and size, material hardness/brittleness and ductility, and particle impact speed and angle. Mechanistic erosion equations that are available in the literature are mostly derived from data pertaining to specific experiments and therefore can’t be applied to all applications without suitable adjustments. Survey of the literature relating to particle-based receivers revealed that the most prevalent approach has been to choose low velocities to limit erosion, but to our knowledge, little effort has been put in to fully characterize erosion at the expected operating conditions. A relatively recent work investigated the erosion of wire mesh proposed for use in a particle receiver, where the results actually showed an increase in mass as oxidation occurred on the mesh surface but the work did not investigate the particle attrition rate, and the erosion rate of a solid substrate. The end goal of this work is to develop a comprehensive particle and substrate durability model that will allow a comprehensive understanding of particle-based CSP operating conditions on component durability.

14 SOLAR ENERGY↗

DOE OSTI2020

An Analytical Model of Erosive Wear of BioMass Comminution Components

An analytical erosion model that relates critical process parameters (speed and impingement angle) to critical material attributes of inorganic mineral species in feedstock (density, size, aspect ratio) and substrate (hardness, toughness, and fatigue ductility) was applied to model wear in pretreatment milling operations. Results of the model were compared to experimental measurements of wear produced using the Accelerated Wear Test (AWT) rig at Idaho National Laboratory (INL). Results showed that there is good agreement between predicted and measured performance, and that a quality-by-design (QbD) tool can be developed to predict component reliability based on scientific engineering principles in lieu of trial-and-error approaches.

09 BIOMASS FUELS↗

DOE OSTI2020

Application of an Erosion Wear Model to Predict Wear of Hammer Milling Components

A workable analytical erosion model that relates critical hammermill process parameters (hammermill geometry and rotational speed) to critical material attributes of inorganic mineral species in feedstock (density, size, and aspect ratio) and substrate (hardness, toughness, and fatigue ductility) was applied to model wear (more specifically, change in the shape of hammers) in hammer milling operations. Results of the model were compared to experimental observations of the shape of hammers used in the INL Stage 1 Vermeer hammermill. Results showed good agreement between predicted and measured shape of the hammer, and that a quality-by-design (QbD) approach can be developed to predict component reliability based on scientific engineering principles in lieu of trial-and-error approaches.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Solid-State Joining of Magnesium Sheet to High-Strength Steel

Increasing the use of lightweight materials and implementing enabling manufacturing technologies are the two primary paths toward automotive weight reduction. In many situations, the ability to substitute light weight material requires a need to attach and join light weight material to existing steel substructures requiring dissimilar joining technologies. Dissimilar joining methods currently available in cost range for high volume automotive manufacturing face multiple challenges. The problem is exacerbated in the case of Magnesium alloy to steel joints because of their highly dissimilar nature and lack of mutual miscibility. Additionally, Magnesium’s poor room temperature ductility complicates the use of point fastening technologies. Two emerging solid-state joining technologies Friction Stir assisted Scribe welding (FaST) and Ultrasonic Welding (USW) that employ large amount of plastic deformation at the interface were used to investigate, develop, and understand dissimilar joints between Magnesium Alloy to DP590 Steel. Various process responses including interface temperatures, process forces, strain fields were captured during the development of the welding process. Variety of welded samples were tested and characterized to understand the relationship between welding conditions and joints microstructure and mechanical properties.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Preliminary Study of Potential Utilization of Triassic Rift Basins for Long-Term Carbon Sequestration

Triassic rift basins of the eastern United States present a potential option for long–term carbon dioxide (CO 2 ) sequestration. Exposed and buried basins are located near large point CO 2 sources. Because of their similar origins, comparable fill successions indicate a level of reproducibility that can be conveyed between basins. The thick rock successions of the exposed Culpeper and Gettysburg basins served as proxies for understanding of the basin sequences. Their study allowed recognition of five mappable assemblages of rock types, herein termed lithofacies associations. These lithofacies associations were formed by alluvial fan, braided and meandering streams and marginal and distal lake depositional processes.Stratigraphic architecture of the lithofacies associations within exposed basins suggests a vertical succession that consists of an initial coarse-grained fluvial succession that is progressively replaced upward and basinward by finer grained lacustrine deposits. Along the faulted margins of the basins alluvial fans transitioning to fluvial delta deposits reflect lateral progradation and contemporaneous lateral components of the basin filling.To test the model devised in exposed basins, facies associations were developed for the buried Taylorsville Basin. This basin preserves over 8,000 feet of Triassic rocks that are concealed beneath more than 2,000 feet of Cretaceous and Tertiary Coastal Plain sediments. Composition and stratigraphic architecture of these rocks are similar to those observed in exposed basins. Infilling of the basin was the result of vertical aggradation and lateral progradation of coarse-grained to fine-grained facies. Based upon study of outcrops in the Culpeper and Gettysburg basins, groups of recurring lithologic facies were identified as the fundamental constructs of the basin’s sediment infilling. These groups of facies, termed lithofacies associations, represent an amalgamation of lithologic components from broadly similar depositional systems. These lithologic associations were then extrapolated into the exposed and buried portions of the Taylorsville basins. This effort determined that Triassic rift basins provide several avenues for potential study of geologic sequestration of carbon. The characteristic rift basin succession in the basins presents possible reservoir targets within the marginal fluvial deposits. Furthermore, intrusive and extrusive mafic bodies present a potential source of fracture porosity that could serve as CO 2 reservoirs. Porosity values from thin section analysis of exposed basin samples are higher in alluvial fan and braided fluvial lithofacies. Porosity is highest in samples that show less compaction, due to a lack of ductile lithic fragments and/or higher stratigraphic position. Log data from the Taylorsville Basin indicates that porosity and permeability values in basin marginal fluvial strata are elevated. Near the center of the basin, porosity and permeability values are greatly reduced, primarily owing to the fine-grained character of the lacustrine deposits. Some Triassic basins also contain thick intervals of concordant extrusive and intrusive mafic igneous rocks. These igneous bodies are potential CO 2 reservoirs for several reasons. Firstly, extrusive lava flows provide potential storage in the layers of primary porosity that occur in the vesicules formed at the top of lava flows. Secondly, both lava flows and subsurface igneous sills exhibit extensive fracture porosity produced by the rapid cooling of the flows and intrusions. Thirdly, these igneous rocks are mafic in composition, and studies have shown that iron- and magnesium-rich mafic rocks provide sequestration opportunities through carbonate remineralization. Lastly, extrusive and intrusive igneous rocks are invariably preserved within fine-grained lake deposits. These lacustrine sediments can serve as a fine-grained confining layer that encases the igneous rocks both above and below.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2021

In-situ Radiography of Hydrogen Porosity Growth and Development in Aluminum Welds

In aluminum welding, hydrogen contamination is the main cause of the welding defect, porosity. Porosity in welds can adversely affect the mechanical properties such as tensile strength, fatigue life and ductility. There have been a variety of solutions to help reduce porosity in aluminum welds including finding the source of hydrogen. However, in some cases the amount of hydrogen may be drastically reduced but impossible to completely eliminate. Another approach to this issue is to understand where a pore originates and how it moves and grows within the weld pool. This information may lead to a more innovative method for pore elimination during gas tungsten arc (GTA) welding of aluminum.

42 ENGINEERING↗

DOE OSTI2023

Atomic-Scale Computational and Experimental Investigation of Twinning Mechanisms in HCP Systems

One of the major goals of the Materials Science and Engineering community is to achieve a fundamental understanding of how alloying affects the mechanical properties of structural materials. Titanium (Ti) and its alloys are particularly in demand due to their relatively lightweight, high strength and corrosion resistance. The low-temperature ductility of hexagonal close-packed (hcp) Ti known as α- Ti is linked to twinning. The addition of alloying elements can affect the deformation mechanisms leading to the change in macro-scale mechanical properties. To understand these effects, our objective is to study and quantify the energetics and kinetics of substitutional and interstitial solutes on the deformation mechanisms of hcp alloys.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Corrosion Behavior Characterization of Tantalum in Flowing LBE [Slides]

Tantalum is a refractory metal, it has low coefficient thermal expansion and high creep resistance. Its BCC structure makes Ta less prone to radiation damage. It is 2nd most ductile among refractories. Its oxide (Ta 2 O 5 ) layer is thin and stable at high temperatures and low oxygen concentrations.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2020

Mechanical testing of PH13-8Mo H950 Steel for Xue-Wierzbicki Fracture Criterion Determination at 20° C and -40° C

Mechanical testing was conducted to collect the data needed to build a Xue-Wierzbicki (XW) fracture model for PH13-8 Mo H950 stainless steel (PH 13-8 SS). This model is intended for use in structural analysis of this material between room temperature and -40° C. Tests were performed on four different specimen geometries such that a range of stress states were characterized at room temperature and -40° C. Tensile tests on R5 tensile specimens were also performed to assess material anisotropy. Fracture toughness test were also conducted. The fracture toughness of this material at -40° C was 68% of the room-temperature value. Material strength generally increased with decreasing temperature while the opposite trend was observed for ductility. These trends were most pronounced for specimens with the largest stress triaxialities.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Effect of thermal aging and irradiation on microstructure and crack growth response of Alloy 690

Nickel-base Alloy 690 and the associated weld Alloys 52 and 152 are typically used for nozzle penetrations in replacement heads for pressurized water reactor (PWR) vessels, because of their excellent overall resistance to general corrosion and environmental degradation, primarily stress corrosion cracking (SCC). However, many of the existing PWRs reactors are expected to operate for 40-80 years. Likewise, advanced water-cooled small modular reactors (SMRs) will use Ni-Cr alloys and are expected to receive initial operating licenses for 60 years. Hence, the thermal stability of Ni-Cr alloys is a potential concern for the long-term performance of both existing and advanced nuclear plants, and possibly spent fuel storage containers. The objective of this research is to understand the microstructural changes occurring in high-Cr, Ni-based Alloy 690 during long time exposure to the reactor operating temperatures, and the effect of these changes on the service performance. One area of particular concern is the potential for long range ordering (LRO), i.e. formation of the intermetallic Ni 2 Cr phase under prolonged exposure to reactor temperatures and/or irradiation, which can increase strength, decrease ductility, and cause dimensional changes or lead to in-service embrittlement of components made with these alloys. Hence, this research focused on the microstructural evolution and the SCC response of Alloy 690 under accelerated thermal aging and irradiation conditions. The materials studied involved Alloy 690 from two sources: (i) Alloy 690 plate from an Alloy 152 dissimilar metal weld (DMW) joining the Alloy 690 plate to Alloy 533 LAS, aged at three different temperatures (370°C, 400°C and 450°C) for up to 75,000h (equivalent to 60 years of service), and (ii) specimens neutron-irradiated in the BOR-60 reactor up to 40 dpa. For aged Alloy 690 specimens, hardness was found to increase with aging time, however, the microstructural characterization by means of synchrotron X-ray did not find evidence of LRO. The microstructural characterization of neutron-irradiated specimens by TEM found no evidence of LRO either. Testing in a primary water environment of Alloy 690 specimens aged to a 60-year service equivalent revealed a fatigue and corrosion fatigue crack growth responses similar to those measured on the un-aged alloy. The SCC CGR response was also low. Overall, the two Alloy 690 heats investigated in this work, aged up to 60-year service equivalents or exposed to neutron irradiation up to 40 dpa, did not exhibit a deterioration in microstructure or performance.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2021

Tensile Property and Lifetime Prediction for Low-Temperature Aged Uranium-Niobium Alloys

Thermal aging models and lifetime predictions for uranium-niobium (U-Nb) alloys were created using an approach similar to those previously employed. Lifetime estimates for generic U-6Nb components were thus updated; the reported value being 800 years. This update represents a small change in lifetime vs. that of the 2012 assessment (540 years). This lifetime estimate emerged from consideration of several model fits specific to the aging datasets and properties chosen. Aging was quantified using quasi-static tensile properties measured on specimens artificially aged for up to 10 years. The major change relative to the most recent 2012 LANL assessment was that a more comprehensive body of U-Nb literature data was mined, in addition to being augmented by the latest LANL and UK AWE data. The tensile data compilation was published separately (LANL report LA-14493, December 2016). Recognizing the chemical banding of industrially produced U-6Nb, models were developed for the mid-range (6 wt.%) and extrema (4 and 8 wt.%) compositions. Lifetime estimates were calculated for all three alloy classes (4, 6, 8 wt.% nominal) and two measures of total tensile elongation (TE) to failure, namely TE-ext. — extensometer method, and TE-NCD — normalized crosshead displacement method. The conservative assumption was made that whichever composition (4, 6, or 8 wt.% Nb) and property (TE-ext or TE-NCD) was the first to cross the ductility failure threshold would limit the lifetime of the entire component. Tensile strength properties did not figure into the lifetime predictions, but could be useful as age-sensitive diagnostics and were also modeled. Of these, only first yield strength is expected to show a change at 40°C aging vs. time = 0 over the ~100-year timespan of engineering interest. Second yield strength evolves more slowly, and ultimate tensile strength slower still. Among all the models, the apparent activation energies for aging were mostly in the narrow 29– 37 kcal/mol range, which is close to that for diffusion of Nb in gamma-uranium. This agreement may be coincidental. The data from recent long-term aging studies substantially improved the model fit quality and robustness of the lifetimes. Appendices document sensitivity studies of the model fits and lifetimes with respect to using more limited datasets. These results highlight the limitations of relying solely on data from scattered literature studies and smaller datasets more generally.

36 MATERIALS SCIENCE↗

DOE OSTI2020

STEP Report on Advanced ODS FeCrAl Alloys for Fission Applications

Oak Ridge National Laboratory is developing advanced low-Cr oxide dispersion strengthened (ODS) FeCrAl alloys for accident tolerant fuel (ATF) cladding. This report presents the characterization of two new ODS FeCrAl tubes by using powder commercially mechanically alloyed by Zoz GmbH, which underwent high-precision tube rolling with two different annealing schedules. This work shows that the ODS FeCrAl tube without recrystallization exhibits consistent mechanical behavior in comparison with a previously produced tube. The second tube, which underwent a full recrystallization step before the final tube rolling step, showed some circumferential cracking and exhibited limited ductility in the axial tube tensile tests. Based on current and prior work on the ODS FeCrAl alloy system, this report compares the current state of the scientific literature on the alloy class with that of wrought FeCrAl without oxide additions. Then, this report makes recommendations for future research directions that should be undertaken to increase the technology readiness level for ODS FeCrAl as a viable ATF candidate material. This report has been submitted as fulfillment of milestone M3FT-20OR020202064 titled, “STEP Report on Advanced ODS FeCrAl Alloys for Fission Applications” for the US Department of Energy Office of Nuclear Energy’s Advanced Fuel Campaign of the Fuel Cycle R&D program.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

ASCEND: Asymptotically compatible strong form foundations for nonlocal discretization

Nonlocal models naturally handle a range of physics of interest to SNL, but discretization of their underlying integral operators poses mathematical challenges to realize the accuracy and robustness commonplace in discretization of local counterparts. This project focuses on the concept of asymptotic compatibility, namely preservation of the limit of the discrete nonlocal model to a corresponding well-understood local solution. We address challenges that have traditionally troubled nonlocal mechanics models primarily related to consistency guarantees and boundary conditions. For simple problems such as diffusion and linear elasticity we have developed complete error analysis theory providing consistency guarantees. We then take these foundational tools to develop new state-of-the-art capabilities for: lithiation-induced failure in batteries, ductile failure of problems driven by contact, blast-on-structure induced failure, brittle/ductile failure of thin structures. We also summarize ongoing efforts using these frameworks in data-driven modeling contexts. This report provides a high-level summary of all publications which followed from these efforts.

97 MATHEMATICS AND COMPUTING↗