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DOE OSTI2020

Perspectives on Quenching and Tempering 4340 Steel

Steels are ubiquitous due to their affordability and the landscape of useful properties that can be generated for engineering applications. But to further expand the performance envelope, one must be able to understand and control microstructure development by alloying and processing. In this paper we use multiscale, advanced characterization to better understand the structural and chemical evolution of AISI 4340 steel after quenching and tempering (Q&T), including the role of quench rate and short-time, isothermal tempering below 573 K (300 °C), with an emphasis on carbide formation. We compare the microstructure and/or property changes produced by conventional tempering to those produced by higher temperature, short-time “rapid” tempering. We underscore that no single characterization technique can fully capture the subtle microstructure changes like carbon redistribution, transition carbide and/or cementite formation, and retained austenite decomposition that occur during Q&T. Only the use of multiple techniques begins to unravel these complexities. After controlled fast or slow quenching, η transition carbides clearly exist in the microstructure, likely associated with autotempering of this high martensite start temperature (Ms) steel. Isothermal tempering below 598 K (325 °C) results in the relief of carbon supersaturation in the martensite, primarily by the formation of η transition carbides that exhibit a range of carbon levels, seemingly without substitutional element partitioning between the carbide and matrix phases. Hägg transition carbide is present between 300 °C and 325 °C. After conventional tempering at or above 598 K (325 °C) for 2 h, cementite is predominant, but small amounts of cementite are also present in other conditions, even after quenching. Previous work has indicated that silicon (Si) and substitutional elements partition between the cementite, which initially forms under paraequilibrium conditions, and the matrix. Phosphorous (P) may also be preferentially located at cementite/matrix interfaces after high temperature tempering. Slower quench rates result in greater amounts of retained austenite compared to those after fast quenching, which we attribute to increased austenite stability resulting from “autopartitioning”. Rapid, high temperature tempering is also found to diminish tempered martensite embrittlement (TME) believed to be associated with the extent of austenite decomposition, resulting in mechanical properties not attainable by conventional tempering, which may have important implications with respect to industrial heat treatment processes like induction tempering. Controlling the amount and stability of retained austenite is not only relevant to the properties of Q&T steels, but also next-generation advanced high strength steels (AHSS) with austenite/martensite mixtures.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Flattening of the tokamak current profile by a fast magnetic reconnection with implications for the solar corona

During tokamak disruptions, the profile of the net parallel current is observed to flatten on a time scale that is so fast that it must be due to a fast magnetic reconnection. After a fast magnetic reconnection has broken magnetic surfaces, a single magnetic field line covers an entire volume and not just a magnetic surface. The current profile, given by K ≡ μ 0 j | | / B , relaxes to a constant within that volume by Alfven waves propagating along the chaotic magnetic field lines. The time scale for this relaxation determines the commonly observed disruption phenomena of a current spike and a sudden drop in the plasma internal inductance. An efficient method for studying this relaxation is derived, which allows a better understanding of the information encoded in the current spike and the associated sudden drop in the plasma internal inductance. Implications for coronal heating are also discussed.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

Scalable Multiphysics Block Preconditioning for Low Mach Number Compressible Resistive MHD with Application to Magnetic Confinement Fusion

This study investigates multiphysics block preconditioners that are critical in devising scalable Newton–Krylov iterative solvers for longer time-scale fully implicit fluid plasma models. The specific model of interest is the visco-resistive, low Mach number, compressible magnetohydrodynamics (MHD) model. This model describes the dynamics of conducting fluids in the presence of electromagnetic fields and can be used to study aspects of astrophysical phenomena, important science and technology applications, and basic plasma physics. The specific application of interest that motivates this study is the macroscopic simulation of longer time-scale stability and disruptions of magnetic confinement fusion devices, specifically the ITER Tokamak. The computational solution of the governing balance equations for mass, momentum, heat transfer, and magnetic induction for resistive MHD systems can be extremely challenging. These difficulties arise from both the strong nonlinear, nonsymmetric coupling of fluid and electromagnetic phenomena as well as the significant range of time and length scales that the interactions of these physical mechanisms produce. To handle the range of time and spatial scales of interest, a fully implicit unstructured variational multiscale finite element formulation is employed. For the scalable solution of the Newton linearized systems, fully coupled block preconditioners are designed to leverage algebraic multigrid subsolves. In conclusion, results are presented for the strong and weak scaling of the method as well as the robustness of these techniques for a large range of Lundquist numbers.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2021

Experimental investigation on the coolability of nuclear reactor debris beds using seawater

During the Fukushima nuclear reactor accident, seawater was injected into the reactor core to cool the decay heat from the heat generating porous debris bed. However, the impact of dissolved salts in water on the coolability of a debris bed is not well understood. This paper is one of the first works to investigate the cooling mechanisms for debris bed using seawater. An experimental system was built where the packed bed test section was volumetrically heated via a high frequency induction heater. The temperature along the axis of the test section was measured using a high resolution temperature sensor based on Optical Frequency Domain Reflectometry. Experimental results show that the dryout heat flux increases with an increase in concentration, with pure water having a dryout volumetric heat flux of 1.8 MW/m and salt water of concentration 7% having a dryout volumetric heat flux of 2.8 MW/m. However, this enhanced coolability using salt water is short term, as the crystallization fouling mechanism becomes significant over time and leads to gradual temperature excursion in the bed. The fouling mechanism eventually leads to a cross section of the debris bed to plug with the deposited salts, and this leads to a pressure build up in the lower regions of the debris bed.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2025

Coupled Induction Machine and HVAC Models for Simulating HVAC Performance Considering Grid Dynamics in Buildings

This paper presents the development of novel models that integrate induction machines with HVAC equipment, such as pumps, heat pumps, and chillers, to analyze the impact of electrical parameters on the operational performance of thermo-fluid systems. The proposed model employs a coupling technique that captures the dynamic interactions between induction machines and HVAC systems. By integrating electrical, thermal, and mechanical dynamics, the models provide a comprehensive framework for simulating real-world scenarios, including interactions with the electrical grid. This achievement was made possible through the development of a Computationally Efficient and Accurate Induction Machine (CEAIM) model. Implemented using the equation-based Modelica language, the CEAIM model has been validated against experimental results, manufacturer data sheets, and various operating conditions. Its performance has been compared with existing induction machine models in the Modelica Standard Library (MSL), demonstrating superior accuracy and computational efficiency. The CEAIM model predicts torque, speed, and power consumption with a coefficient of determination (R 2 ) ranging from 0.98 to 1 and a coefficient of variation of root mean square error (CVRMSE) between 0.27% and 6.67%. Additionally, CEAIM scales more efficiently than conventional MSL models, with a slower computational growth rate in large-scale simulations. After thorough validation of the CEAIM model, it was coupled with HVAC equipment as this approach provides a detailed multi-dimensional view of capturing electrical transients and mechanical performance. To support this, a case study was conducted to showcase its capabilities.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2021

In situ TEM observation of calcium silicate hydrate nanostructure at high temperatures

Fire poses a substantial threat to concrete structures because calcium silicate hydrate (C-S-H) is not thermally stable at high temperatures. Herein, in situ TEM at temperatures from 20 to 800 °C was conducted to study the thermal-induced structural changes in C-S-H. We captured C-S-H shrinks at an average rate of 0.02 μm{sup 2}/{sup o}C upon heating with three stages observed, including induction, constant, and rapid periods. Our observation revealed that an 800 nm pore could be healed during pore structure evolution owing to the reconstruction and deformation among C-S-H blocks. The Ca/Si ratio was dropped at higher temperatures because of the leakage of calcium ions from the C-S-H structure to form CaO precipitates. The temperature-driven phase transformation and degradation were also detected using electron diffraction that C-S-H was transformed into metastable calcium silicate minerals above 800 °C. This work provides insights into the nanoscale transformation of C-S-H at high temperatures.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Effect of a liquid-type temperature rise inhibitor on cement hydration

A liquid-type temperature rise inhibitor (L-TRI) based on modified sorbitol was developed to solve the thermal cracking issue by modulating the heat release from cement hydration during the early age. Both the exothermic process and phase evolution of cement pastes blended with/without L-TRI were investigated by the combination of isothermal calorimetry, in-situ XRD, ICP-OES and SEM. Also, the adsorption of the L-TRI in the cement paste was identified by total organic carbon analysis. The testing results suggested that the L-TRI affected the heat flow curve in two ways. It prolonged the induction period as a retarding effect. It also reduced the heat flow during the acceleration period and decreased the maximum heat flow as a depressing effect. The retarding effect was mainly caused by the complexation of unabsorbed molecules in the pore solution, and the depressing effect was caused by inhibiting the growth of C-S-H.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Sensitivity Analysis and Control of Induction Cooktop for Non-Ferromagnetic Cookware

All metal induction cooktop has the potential to enable heating of both ferromagnetic and non-ferromagnetic cookware. Compared to ferromagnetic cookware, the performance of an induction cooktop with non-ferromagnetic cookware is impacted significantly by the cookware misalignment. A detailed sensitivity analysis to the cookware misalignment for non-ferromagnetic cookware is studied in this paper. Based on the analysis, a control architecture is presented which ensures desired power transfer to the non-ferromagnetic cookware and zero voltage turn on of the high frequency inverter irrespective of cookware misalignment. Results are presented to verify the analysis and proposed control strategy.

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

DOE OSTI2023

Variation of γ′ Formers and Refractory Elements for Enhanced Creep resistance and Phase Stability of HAYNES® 282® Alloy

Modifications to the chemistry of alloy 282 were performed to improve the alloy’s resistance to long term creep deformation as well as phase stability. Alloys were prepared using vacuum induction melting, computationally optimized homogenization heat treatment and hot working. Phase stability studies were carried out for up to 5,000 hours at 800°C and 900°C while creep testing was performed at conditions leading to lives past 7,000 hours for temperatures ranging from 740°C to 900°C. The formation of σ and μ phases were reduced in the modified alloy. Atom probe tomography (APT) was performed on the specimens from the phase stability study to investigate changes in the elemental partitioning to the γ and γ′ phases. Post deformation microstructures were analyzed using EBSD and TEM to study the influence of the detrimental phases on damage accumulation during creep.

Detrois, Martin↗

DOE OSTI2026

Oxidation of Materials and Coatings at 1000°C and 250 bar for use in Oxy-Combustion Turbine

Combinations of materials and coatings were tested in supercritical CO2 (sCO2) to evaluate their reliability in an oxy-fuel turbine being designed to operate in the 150-300 MWe size range at inlet temperatures of 1,150 °C at 300 bar and exhaust temperatures in the 725-775 °C range. Nickel alloys and stainless steels were exposed to supercritical CO2 at 1,000 °C and 250 bar for a total of over 1,500 hours. The materials were tested bare, with a nanocrystalline MCrAlY bond coat only, or with one of two types of bond coat and a thermal barrier coating. A novel test facility using a localized heat zone generated by an induction heater inside an externally cooled autoclave was developed to perform those tests. The specimens were weighed before and after exposure to determine the oxidation rate. All specimens were inspected visually, and a smaller group of coated specimens were studied using secondary electron microscopy (SEM). The integrity of the coating, and the morphology and composition of the thermally grown oxide were especially of interest for the SEM investigation. This paper presents the up-to-date results of the testing coated and uncoated superalloys in sCO2 at up to 1150 °C and up to 300 bar performed at Southwest Research Institute.

Bocher, Florent [Southwest Research Institute, San↗

DOE OSTI2020

High-Bandwidth Low-Inductance Current Shunt for Wide-Bandgap Devices Dynamic Characterization

High bandwidth sensors are required to measure the wide-bandgap devices' transient behavior because of their fast switching speed. In addition to high bandwidth, the current sensor must introduce little extra parasitic inductance to the switching power loop. The analysis of conventional shunt resistors shows the key to high bandwidth is the coaxial structure and its parasitic inductance is proportional to its transient heat energy rating. Additionally, by combining the structure of coaxial shunt resistor and alumina substrate surface mount thin film resistors, a novel surface mount coaxial shunt resistor is introduced. Experimental measurement verifies its capability of achieving very high bandwidth while introducing very low parasitic inductance. The design can achieve up to 2.23-GHz measurement bandwidth while keeping its parasitic inductance as low as 0.12 nH. Application in gallium nitride heterojunction-field-effect-transistors double pulse test shows it can faithfully capture the transient current waveform while introducing little interference to the switching behavior.

42 ENGINEERING↗

DOE OSTI2023

Effects of Encapsulant Properties on the Thermo-Mechanical Reliability of Double-Side Cooled Power Modules for Traction Inverters

Double-side cooled power modules are being developed for next-generation traction inverters due to their better heat extraction, lower profile, and lower parasitic inductances. However, due to their rigid structure, they cause reliability concerns arising from high thermo-mechanical stresses at the interconnection joints in the module. In this work, a materials-based approach using rigid encapsulants is presented for reducing thermo-mechanical fatigue. Finite-element thermo- mechanical simulations were performed to examine the effects of the elastic modulus and coefficient of thermal expansion of epoxy- based encapsulants on the bond deformation inside a double-side cooled power module. It was found that a rigid encapsulant with a high modulus of 6.0 GPa or above and a coefficient of thermal expansion around 20 ppm/oC would improve the thermo- mechanical reliability of double-side cooled power modules by decreasing the permanent bond deformation inside the modules by 50-60%.

ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2021

Effect of ZnO on the whiteness of white Portland cement clinker

The addition of ZnO to significantly improve the Hunter whiteness of white Portland cement (WPC) clinkers is introduced in this paper. The effects of ZnO on the whiteness of WPC were studied by chroma analysis, X-ray diffraction (XRD), the Rietveld method, hydration heat measurements and SEM-EDS. The results showed that adding ZnO increased the visible light reflectance, increased the brightness (L{sup ⁎}), and reduced the yellowness (b{sup ⁎}) of WPC clinker with high Fe{sub 2}O{sub 3}. Therefore, ZnO can increase the whiteness of WPC clinker. Zn was mainly distributed in the amorphous phase and unquantifiable crystalline phase (ACn), and then dissolved in the silicate phase. ZnO stabilized R-C{sub 3}S, reduced the crystallization of C{sub 3}A, and increased the ACn content. ZnO increased the amount of Fe in the ACn and minerals, thereby reducing the formation of C{sub 4}AF and improving whiteness. ZnO increased the accumulated heat of hydration but prolonged the induction period. This method provides a new approach for the WPC industry to broaden sources of raw materials and improve product quality.

36 MATERIALS SCIENCE↗

DOE OSTI2024

NSTX-U research advancing the physics of spherical tokamaks

Abstract The objectives of NSTX-U research are to reinforce the advantages of STs while addressing the challenges. To extend confinement physics of low- A , high beta plasmas to lower collisionality levels, understanding of the transport mechanisms that set confinement performance and pedestal profiles is being advanced through gyrokinetic simulations, reduced model development, and comparison to NSTX experiment, as well as improved simulation of RF heating. To develop stable non-inductive scenarios needed for steady-state operation, various performance-limiting modes of instability were studied, including MHD, tearing modes, and energetic particle instabilities. Predictive tools were developed, covering disruptions, runaway electrons, equilibrium reconstruction, and control tools. To develop power and particle handling techniques to optimize plasma exhaust in high performance scenarios, innovative lithium-based solutions are being developed to handle the very high heat flux levels that the increased heating power and compact geometry of NSTX-U will produce, and will be seen in future STs. Predictive capabilities accounting for plasma phenomena, like edge harmonic oscillations, ELMs, and blobs, are being tested and improved. In these ways, NSTX-U researchers are advancing the physics understanding of ST plasmas to maximize the benefit that will be gained from further NSTX-U experiments and to increase confidence in projections to future devices.

74 ATOMIC AND MOLECULAR PHYSICS↗

DOE OSTI2021

3-D Prismatic Packaging Methodologies for Wide Band Gap Power Electronics Modules

In a power module the parasitic inductance limits the dynamic high-frequency performance, and the area of the cooling surfaces limits the power capability. This paper presents a new 3D power electronic design methodology based on the concept of mutual inductance cancellation and multi-sided heat transfer. New 3D prismatic packaging concepts are proposed for Wide Band Gap (WBG) power devices, where the devices can be mounted at acute angles to adjacent interconnects or other devices. Discussion is given on electrical and thermal path optimization in a 3D space. To validate the 3D prismatic packaging methodology, a 1200V/50A SiC half-bridge power module is fabricated and tested for electrical and thermal performance and results are compared with simulations. The power density calculated for the module is 12 kW/in3 (including heatsink) and shows a 31.3% inductance reduction compared to a 2D planar module. Finally, design guidance suggested for utilizing prismatic structures is provided, together with suggested future work in the area. This paper presents the first reported true 3D power module.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2022

Time-resolved 3D characterisation of early-age microstructural development of Portland cement

Abstract Time-resolved in-situ synchrotron X-ray microtomography reveals new levels of detail about the chemical and physical processes that take place as Portland cement hardens. The conversion of a fluid paste into a hardened product can be monitored on a sub-minute time-scale, and with sample movement/settlement corrections applied to enable individual particles to be tracked as they react, hydrate, and become interconnected into a single strong monolith. The growth of the strength-giving hydrate phases surrounding cement grains, and of the fluid-filled pore network that surrounds them, is able to be directly viewed at the level of individual cement particles through the application of this tracking protocol. When cement is brought into contact with water, a layer which differs in density from the bulk of the cement grains becomes observable on the grain surfaces during the induction period (during which time the heat evolution from the paste is relatively low). As hydration continues, reaction products grow both from particle surfaces into the initially fluid-filled region, and also into the space originally occupied by the cement particles, forming a density gradient within the microstructure. As the reaction accelerates and larger volumes of solid phases precipitate, the newly-formed solid structure percolates via interconnection of agglomerated low-density outer hydrates, which then densify as hydration continues. This eventually leads to solidification of the structure into a hardened porous matrix. Graphical abstract

36 MATERIALS SCIENCE↗

DOE OSTI2023

Disposition of Solids from Hydrothermal Liquefaction of Biomass: Current Understanding, Research Gaps, and Opportunities

Characteristics of solid residuals generated during hydrothermal liquefaction (HTL) of biomass are reported to establish disposition options for these residuals to reduce liability or barriers to commercialization of HTL. HTL solids from pilot scale are reported and compared to existing HTL solids literature for a variety of biomass feedstocks and HTL configurations, noting differences among literature HTL solids due to solids collection methods. Reported analyses include CHNOS, moisture, ash, inorganics by Inductively Coupled Plasma (ICP), and High Heating Value (HHV). HTL solids are determined to be substantially compatible with U.S. Environmental Protection Agency (EPA) disposal regulations within existing data. Disposition and valorization routes are identified, yet combustion as valorization is determined to be not economically beneficial. Further, research gaps are identified, which include the need for future research to be performed on HTL solids that are representative of a continuous, commercializable flowsheet; verification that specific HTL solids meet EPA disposal requirements; exploration of valorization options; and the need for invention of continuous HTL solids separations/management.

09 BIOMASS FUELS↗

DOE OSTI2021

A Double-side Cooled SiC MOSFET Power Module with Sintered-silver Interposers: I. Design, Simulation, Fabrication, and Performance Characterization

Planar, double-side cooled power modules are emerging in electric-drive inverters because of their low profile, better heat extraction, and lower package parasitic inductances. However, there is still concern about their reliability due to the rigid interconnection between the device chips and two substrates of the power module. In this paper, a porous interposer made of low-temperature sintered silver is introduced to reduce the thermo-mechanical stresses in the module. A double-side cooled half-bridge module consisting of two 1200 V, 149 A SiC MOSFETs was designed, fabricated, and characterized. By using the sintered-Ag instead of solid copper interposers, our simulation results showed that at a total power loss of 200 W, the thermo-mechanical stress at the most vulnerable interfaces (interposer-attach layer) was reduced by 42 % and in the SiC MOSFET by 50 % with a trade-off of only 3.6 % increase in junction temperature. The sintered-Ag interposers were readily fabricated into desired dimensions without post-machining and did not require any surface finishing for die-bonding and substrate interconnection by silver sintering. Here, the porous interposers were also deformable under a low force or pressure, which helped to accommodate chip thickness and/or substrate-to-substrate gap variations in the planar module structure, thus simplifying module fabrication. Experimental results on the electrical performance of the fabricated SiC modules validated the success of using the porous silver interposers for fabricating planar, double-side cooled power modules.

42 ENGINEERING↗