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

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At least 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Updated ASME design correlations and qualification plan for powder bed fusion 316H stainless steel

This report provides an update on the Advanced Materials and Manufacturing Technologies (AMMT) program effort to qualify Laser-Powder Bed Fusion (L-PBF) 316H stainless steel for use with the ASME Boiler & Pressure Vessel Code Section III, Division 5 rules. The report summarizes progress in testing and characterizing L-PBF material at elevated temperatures by providing preliminary design data for L-PBF 316H and by comparing the elevated temperature performance of the L-PBF material to wrought and conventional fusion welded 316H. The report then updates the initial AMMT qualification plan for L-PBF 316H, originally developed in 2023, to update the accelerated qualification strategy adopted in that plan to account for the new high temperature test data. The report also explores a few methods for further accelerating the qualification process using machine learning techniques to supplement the more conventional, empirical analysis methods typically used by ASME to correlate and extrapolate time-dependent material test data.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Operating a full tungsten actively cooled tokamak: overview of WEST first phase of operation

WEST is an MA class superconducting, actively cooled, full tungsten (W) tokamak, designed to operate in long pulses up to 1000 s. In support of ITER operation and DEMO conceptual activities, key missions of WEST are: (i) qualification of high heat flux plasma-facing components in integrating both technological and physics aspects in relevant heat and particle exhaust conditions, particularly for the tungsten monoblocks foreseen in ITER divertor; (ii) integrated steady-state operation at high confinement, with a focus on power exhaust issues. During the phase 1 of operation (2017–2020), a set of actively cooled ITER-grade plasma facing unit prototypes was integrated into the inertially cooled W coated startup lower divertor. Up to 8.8 MW of RF power has been coupled to the plasma and divertor heat flux of up to 6 MW m –2 were reached. Long pulse operation was started, using the upper actively cooled divertor, with a discharge of about 1 min achieved. This paper gives an overview of the results achieved in phase 1. Perspectives for phase 2, operating with the full capability of the device with the complete ITER-grade actively cooled lower divertor, are also described.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Feature Based Qualification of 17-4PH Stainless Steel to Evaluate Location-Specific Variability in Wire Arc Additive Manufacturing

Qualifying large-scale metal additive manufacturing (M-AM) technologies such as wire arc additive manufacturing (WAAM) can be challenging. This is especially significant in precipitation hardened martensitic stainless steels like SS 17-4PH, where thermal histories induce location-specific microstructural variability and property anisotropy. The Department of Defense (DOD) and the United States Army Combat Capabilities Development Command Ground Vehicle Systems Center (GVSC) Ground Vehicle Materials Engineering (GVME) aim to build robust and qualified large-scale M-AM workflows that could reduce the time and cost through quick and informed evaluation, testing, and development of feedstock, processes, and parts. The report presents the findings from the collaborative efforts between Oak Ridge National Laboratory (ORNL) and the U.S. Army GVSC GVME. The aim of this project was to develop a geometric feature-based qualification framework for WAAM of SS 17-4PH components. This report outlines selection methodology of representative build geometries, optimization of WAAM process parameters, in-situ monitoring, microstructure-property evaluation, thermal simulations, as well as data visualization techniques incorporated in this project. The results from this project demonstrate a clear understanding of thermal history dependent phase evolution and consequent location-specific property variations in WAAM of SS 17-4PH. These results in conjunction with the data-driven methodologies used in this project are expected to reduce qualification timelines, improve predictability, and accelerate the development of reliable feature-based qualification strategies for part production via large-scale M-AM technologies.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Sizing and Selection of Pressure Relief Valves for High-Pressure Thermal–Hydraulic Systems

This study covers the critical concerns related to the sizing, selection, installation, maintenance, and testing of pressure safety valves (PSVs). The aim is to ensure the safety of pressurized systems, hydrostatic transmission systems, and hydraulic plants, including process plants, thermal power plants, and nuclear reactor systems. PSVs are devices that ensure the safety and reliability of pressurized vessels, lines, and systems during overpressure events. The task of selecting which PSV features are of greatest value for a specific purpose is complex—especially in the design of a high-pressure experimental thermal–hydraulic facility for hydrostatic and transient testing of the reactor system—when the systems are in the design and development phases and require qualification and demonstration to prove that they have reached a given level of technological readiness. The present study highlights the required steps for users to follow the associated rules, guidelines, and recommendations. As a part of this research, case studies are presented to help readers better understand the applicable strategy and standards. A discussion and a review of PSV performance degradation and failure are summarized to provide a better understanding of varied process applications and conditions, including fluid flow dynamics, boundary-layer formation and pressure drops, gas bubble formation and collapse, geometric configurations, inlet/outlet piping, abrupt pressure fluctuations, and acoustic resonance. Moreover, this study discusses the servicing and testing of PSVs in a multiphase pressurized system. Overall, it provides a basic overview of how PSVs ensure the safety of pressurized systems, supported by case studies and industrial practices.

02 PETROLEUM↗
DOE OSTI2024

Scientific Foundations and Approaches for Qualification of Additively Manufactured Structural Components

Additive manufacturing (AM) maintains a wide process window that enables complex designs otherwise unattainable via conventional production technologies. However, the lack of confidence in qualifying AM parts that leverage AM process–structure–property–performance (PSPP) relationships stymies design optimization and adoption of AM. While continuing efforts to map fundamental PSPP relationships that cover the potential design space, we first need pragmatic and then long-term solutions that overcome challenges associated with qualifying AM-designed parts. Two pragmatic solutions include: (1) AM material specifications to substantiate process reproducibility, and (2) component risk categorization to associate system risk relative to part performance and required part quality. A novel qualification paradigm under development involves efficient prediction of part performance over wide-ranging PSPP relationships through targeted testing and computational simulation. Here this paper describes projects at Sandia National Laboratories on PSPP relationship discovery, these pragmatic approaches, and the novel qualification approach.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Environmental Degradation in Advanced Reactor Environments

The Advanced Materials and Manufacturing Technologies (AMMT) program operating under the Department of Energy Office of Nuclear Energy is accelerating the qualification and deployment of additively manufactured materials in advanced reactor environments. Laser powder bed fusion (LPBF) has emerged as a promising additive manufacturing technique to fabricate complex components with the potential of tailored material properties. In the nuclear industry, metal additive manufacturing can offer numerous advantages, such as reduced lead times, streamlined quality assurance, and cost-effective low-volume production of new and replacement components with conventional or novel materials and geometries. The rapid and effective qualification of the effect of processing variability on the performance and degradation of additively manufactured materials is essential for the deployment of these components into advanced reactor environments. This talk presents an overview of the Environmental Effects area activities within AMMT. AMMT is performing irradiation and corrosion testing of several materials built by LPBF, including 316L and 316H stainless steels. Our irradiation efforts encompass neutron irradiation testing and ion irradiation testing to provide a robust technical basis for understanding the effect of process variability on materials degradation. We develop focused irradiation test plans that align well with risk-informed and technologically inclusive approaches to licensing. We will also discuss our plans and specific concerns for corrosion testing additively manufactured material, with a primary focus on molten salt and liquid sodium environments.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Irradiation and corrosion testing of laser powder bed fusion-manufactured materials in the AMMT program

The Advanced Materials and Manufacturing Technologies (AMMT) program operating under the Department of Energy Office of Nuclear Energy is accelerating the qualification and deployment of additively manufactured materials in advanced reactor environments. Laser powder bed fusion (LPBF) has emerged as a promising additive manufacturing technique to fabricate complex components with the potential of tailored material properties. In the nuclear industry, metal additive manufacturing can offer numerous advantages, such as reduced lead times, streamlined quality assurance, and cost-effective low-volume production of new and replacement components with conventional or novel materials and geometries. The rapid and effective qualification of the effect of processing variability on the performance and degradation of additively manufactured materials is essential for the deployment of these components into advanced reactor environments. As part of this effort, AMMT is performing irradiation and corrosion testing of several materials built by LPBF, including 316L and 316H stainless steels. Our efforts encompass neutron irradiation testing, ion irradiation testing, and advanced modeling to provide a robust technical basis for understanding the effect of process variability on materials degradation and developing a sound methodology for accelerated ion irradiation testing. We develop focused irradiation test plans that align well with risk-informed and technologically inclusive approaches to licensing. We will also discuss our plans and specific concerns for corrosion testing additively manufactured material, with a primary focus on molten salt and liquid sodium environments.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2023

BISON validation to in situ cladding burst test and high-burnup LOCA experiments

The process for developing and qualifying nuclear fuels for commercial nuclear application requires fundamental material development, characterization, and design; out-of-pile testing on unirradiated materials; integral fuel rod irradiations, testing, and postirradiation examinations; and transient analyses. The historical approach depends on the generation of large empirical datasets and series of integral fuel rod irradiations, and this approach ultimately takes ~20 years—or sometimes longer—to acquire data through extensive sequential testing. Thus, the qualification and eventual deployment of new fuel systems constitute a long process. However, recent technological advancements have provided researchers the opportunity to perform out-of-cell, in situ measurements to assess material performance for the duration of the experiment. One such example of this capability is the use of digital image coordination and thermal imaging to assess Zircaloy cladding performance under a simulated loss-of-coolant accident (LOCA) transient condition. In situ measurements generally provide high-fidelity strain, strain rates, and temperature surface maps. This is critical for the US nuclear industry, which is actively developing a technical basis to support extending the peak rod average burnup from 62 to ~75 GWd/tU and the deployment of accident-tolerant fuel. However, the US Nuclear Regulatory Commission (NRC) outlined in its research information letter several technical issues that the industry must address before extending burnup. One topic of specific interest is understanding the cladding balloon and rupture geometry during the LOCA heat-up phase. By leveraging these advanced in situ capabilities, this work used in situ data generated from a simulated LOCA to better understand high-temperature creep and its effect on Zircaloy balloon and rupture performance. Here, this work used the BISON fuel performance code to assess the high-temperature creep model predictions with in situ data.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Qualification of an Additively Manufactured Irradiation Capsule for the High Flux Isotope Reactor

As part of the Advanced Materials and Manufacturing Technologies (AMMT) Program’s work package Component Manufacturing and Demonstrations from AM 316 SS, irradiation capsules have been additively manufactured (AM) from 316H stainless steel for insertion into the High Flux Isotope Reactor (HFIR) at Oak Ridge National Laboratory (ORNL). The irradiation capsules (commonly referred to as “rabbits”) have been successfully designed, fabricated, pressure tested, qualified, and inserted into the HFIR for irradiation and post-irradiation evaluation. Each rabbit consists of an AM housing and two standard AM end caps. The design is simple and amenable to geometric and material customization. This demonstration helps pave the way for acceptance of AM safety-critical components for nuclear energy applications.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

MRP: Qualification of Powder Metallurgy Hot Isostatic Pressed (PM HIP) Materials for Elevated-Temperature Nuclear Construction

PM HIP is a mature technology that offers many advantages that are attractive to the microreactor industry. The elevated-temperature creep-fatigue properties of the PM HIP 316H SS bar that has been characterized are reduced compared to the wrought material. Work will be carried out in fiscal year 2022 to identify the mechanisms responsible for the reduced creep-fatigue properties. Confirmatory testing of optimized material will be conducted to demonstrate long-term PM HIP properties comparable to the wrought-product form. The lessons learned for PM HIP 316H SS will be applied to the procurement and confirmatory testing of PM HIP Alloy 800H.

316H stainless steel↗
DOE OSTI2024

Defect Production and Microstructural Feature Impact for Radiation Damage in Additively Manufactured 316 Stainless Steel

This milestone presents multi-scale modeling research results for additively manufactured 316 stainless steel. A combination of phase field, cluster dynamics, molecular dynamics, and density functional theory with machine learning is used, allowing for predictions of radiation-driven microstructural evolution in additively manufactured 316 stainless steel over a range of temperatures, damage rates, neutron spectra, and microstructures, and supporting the development of combined ion and neutron irradiation for material qualification. Informed by ion irradiation and neutron irradiation results across the Advanced Materials and Manufacturing Technologies program, we investigate the unique aspects of radiation-driven microstructure evolution in additively manufactured 316 stainless steel. In particular, we focus on understanding the impact of carbon concentration (varying, for example, between the 316L and 316H standards) on void formation; radiation-induced segregation at dislocation cells and grain boundaries; and the evolution of dislocation loops and network dislocation populations. We find that the unique characteristics of the additively manufactured microstructures must be accounted for in understanding the evolution of dislocation populations under thermal and irradiation conditions, such as the variation in sink strengths arising due to the variation in dislocation density. We also find that the radiation-induced segregation of Cr and Ni to grain boundaries and cell walls differs due to the differences in their defect sink biases. We also find that increasing the Ni content can slow vacancy diffusion, which may provide a mechanism for the observed reduction in transient swelling rate for austenitic Fe-Cr-Ni alloys with increasing Ni content. In addition, ion irradiations have shown that increasing carbon content in 316 SS results in a larger population of smaller voids, suggesting reduced vacancy diffusion. Our results show that the carbon content of additively manufactured 316 SS has a significant impact on the migration rate of defect clusters. The presence of carbon atoms results in carbon-vacancy trapping, significantly reducing the diffusion rate of vacancies. Carbon atoms may also be trapped near the surface of a void, which may reduce void growth by trapping vacancies that diffuse toward the void.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Multi-Modal Characterization of Interfacial Corrosion of Ni-based Alloys in Chloride-based Molten Salts

The United States Department of Energy (DOE) is committed to the advancement of nuclear reactor technology through initiatives such as the Advanced Reactor Development Program (ARDP), to diversify the United States energy portfolio towards more sustainable energy options. The ARDP includes demonstration by industry partners of molten salt fast reactors (MSRs). Construction of molten salt reactor technology requires qualified nuclear structural materials. Unfortunately, there are no current materials that meet current qualification requirements dictated by the Nuclear Regulatory Commission for construction of MSRs. Adapting current structural material qualifications requires expansion of our current knowledgebase on corrosion performance. In this investigation, we assess microstructural changes in a Ni-based superalloy after exposure to a chloride-containing salt system through a correlated multi-modal approach combining several advanced characterization techniques. Namely we will highlight the impact of grain boundary phenomena at the onset of corrosion attack, including the role of intergranular crack propagation and development of internal corrosion products. The findings from this investigation will further expand our assessment of the corrosion performance of structural materials being investigated for construction of MSR components.

36 - MATERIALS SCIENCE↗
DOE OSTI2025

Post-build stress-relief optimization for laser powder bed fusion 316H stainless steel

Nuclear energy remains a critical component of a diversified and efficient energy portfolio, offering reliable, high-capacity, and low-carbon power. However, in the U.S., aging infrastructure and the slow qualification and deployment of advanced materials and manufacturing techniques hinder progress in next-generation reactor technologies. This study explores the application of laser powder bed fusion (LPBF) additive manufacturing for stainless steel 316H, with a focus on optimizing post-build heat treatments to enhance material properties for high-temperature nuclear applications. The research targets the optimization of stress-relief temperatures to alleviate postbuild residual stresses, ensuring improvements in the microstructural corelated properties. A series of microstructural and mechanical evaluations were performed on LPBF-printed SS-316H samples which were subjected to annealing at temperatures varying between 650 °C and 850 °C. X-ray diffraction, scanning electron microscopy, and transmission electron microscopy analyses revealed that increasing the heattreatment temperature accelerated dislocation recovery. Vickers microhardness measurements showed an initial reduction in values, followed by stabilization over extended durations at all the temperatures. While higher temperatures facilitated faster recovery, they also promoted carbide precipitation along grain and solidification cell boundaries, narrowing the safe processing window. In contrast, heat treatment at 650°C preserved the cellular substructure and enabled controlled carbide precipitation over time. In conclusion, these findings highlight the importance of time–temperature optimization and suggest that 650°C for up to 2 h provides the most favorable balance between recovery and carbide control for a stress-relief treatment.

316 stainless steel↗
DOE OSTI2023

Model-based quantification of margins and uncertainties in metal additive manufacturing for process design and qualification

Laser powder bed fusion (LPBF) Additive Manufacturing (AM) has the potential to enable the production of components with novel designs and material properties unachievable otherwise. However, process repeatability is a challenge, making qualification ill-defined and greatly reducing the utility of what could be an important manufacturing technology. In this work, a combination of modeling, uncertainty quantification (UQ), and experimentation are used in an effort to predict and bound the range of possible outcomes of the LPBF process. Quantities of interest predicted are melt pool dimensions, microstructure features, and mechanical distortions. A combination of high fidelity thermal-fluid models, microstructure growth models, and reduced fidelity, rapid thermal and mechanical models are used. Uncertainty propagation techniques are used to predict probability distributions of quantities of interest from estimates of process uncertainties. Repeated experiments are done to quantify observed probability distributions and compared to predicted distributions to determine if predictions are precise and accurate. Novel modeling methods are microstrucutre characterization techniques are also discussed. It is found that high fidelity models do a generally good job bounding experimentally observed melt pool morphologies for both bead-on-plate and powder bed cases. Microstructure models are able to bound a number of experimentally observed microstructure statistics, but with low precision due to challenges with calibrating the microstructure growth model parameters. A developed modified inherent strain distortion model does not accurately predict observed distortions. A lumped laser distortion model shows promise in being both accurately and precisely bounding observed outcomes from the deflection comb build, but requires further evaluation on more builds and geometries.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Comparative analysis of energy deposition modes available in Serpent 2 within the framework of the supercritical water reactor - Fuel qualification test reactor physics benchmark

A joint European Canadian Chinese development of a supercritical water-cooled small modular reactor (SCW-SMR) technology is in progress since September 2020 in the framework of a Horizon 2020 project called ECC-SMART. As a main purpose of the project, proper estimates of energy deposition and its spatial distribution are prerequisites for the accurate analysis of safety related parameters of the SCW-SMR concept under development. A supercritical water reactor fuel computational benchmark model, provided by Canadian Nuclear Laboratories, was applied for detailed comparison of different energy deposition calculation options available in the Serpent 2 Monte Carlo code. The effect of energy deposition options on the normalization of the results as well as on the spatial distribution of the energy deposition are discussed. Consistent energy deposition calculation methods are presented between three Monte Carlo codes, viz., Serpent 2, MCNP6 and OpenMC. Although resource-intensive, the use of the coupled neutron-photon transport mode of Serpent 2 is recommended for accurate spatial and quantitative characterization of energy deposition in the SCW-SMR fuel assemblies, accounting for both neutron and photon heating of all the materials. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2024

Heliostat Observation System Commercialization Qualification HOS-C-Q (Final Technical Report)

Heliostat fields are one of the main components of a concentrated solar thermal plant. As GEN3 technology has been developed at pilot plant level targeting higher temperatures >700C, having a precise Heliostat field control system will enable the success of the GEN3 technology. Heliogen Inc. has developed the next generation of control systems for heliostat fields. Their early development was on single facet heliostats at their R&D facility in Lancaster, California. This new system allows for a closed loop integration to a current open loop setup of a regular Heliostat control system. Sandia National Laboratories and Heliogen Inc. have partnered together to test Heliogen’ s innovative new SOHOT system at the National Solar Thermal Test Facility.

14 SOLAR ENERGY↗
DOE OSTI2022

Interim Report on FY22 ORNL A709 Welding Research and Testing of Production Welds in Support of Developing ASME A709 Code Case Data Package

As part of the Alloy 709 ASME Code Case development effort under the Advanced Reactor Technologies (ART) Program, this work covers the development of the technical basis for weld fabrication and weld qualification of Alloy 709. This report summarizes the Alloy 709 welding research conducted at Oak Ridge National Laboratory (ORNL) in FY 2022. Two new production welds were fabricated on two commercial heats of Alloy 709 of different phosphorus (P) levels using Alloy 709 filler metal with P content less than 20 wppm with gas tungsten arc welding (GTAW). Both production welds successfully passed ASME Section IX weld qualification tests, and this concludes the Alloy 709 welding procedure development to scale up to 2-in thick plates. In FY 2022, we also demonstrated the success in welding of high P commercial Alloy 709 plates with weld wires having higher P content at 30 wppm. A test weld fabricated with the 30 wppm weld wire on the first commercial heat (140 wppm P) passed all weld qualification tests without issues. Additionally, experiment setup and testing procedure of the circular patch weldability test has been developed, for evaluating the P effect in weld wire on solidification cracking susceptibility of Alloy 709 weld, with the preliminary results summarized in this report. Research on further relaxing the P level restriction beyond 30 wppm are planned in FY 2023. The preliminary cross-weld creep tests results continue to show little or no creep strength reduction relative to the base metal.

36 MATERIALS SCIENCE↗