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All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Detailed Design and Cost Estimation of a 300 MWe Oxy-Fuel sCO2 Turbine

The detailed design of a 300 MWe, utility scale oxy-fuel turbine has been completed for purposed operation in the sCO2 direct fired Allam-Fetvedt cycle, targeting near-zero emissions and a 50% LHV system efficiency. The turbine and its supporting plant aim to offer a lower levelized cost of energy than a natural gas combined cycle plant employing carbon capture. The oxy-fuel turbine conditions include an inlet temperature of 1150°C and inlet pressure of 305 bar, representing temperatures near that of a gas turbine simultaneously with pressures near an ultra-supercritical steam turbine. The combustor housing and turbine designs were completed according to the ASME BPVC; the turbine case specifically incorporates a multi-body design with inner high-pressure barrel case and low-pressure (30 bar) horizontally split outer case of low-chromium steel material. Lateral rotordynamic evaluation demonstrated acceptable vibration response for a range of imbalance conditions per API standards. The cooling flow required in the six-stage turbine flowpath for 30,000 hr. blade and stator lifetime is predicted through thermal and structural modeling of the first stage. The provided cost estimate of the turbine is formed through a combination of scaled up-costs from procured 10 MWe scale sCO2 turbomachinery hardware, and vendor provided budgetary quotes of larger components including the turbine case requiring casting, welding, and final machining processes. The performance and cost estimation of the oxy-fuel turbine predicted for the completed detailed design provides important information towards future development needs for market penetration of utility scale direct fired sCO2 power cycles.

Marshall, Michael [Southwest Research Institute, S↗
DOE OSTI2021

CACTI ARM Mobile Facility (AMF) Measurements of Ice Nucleating Particles

The dataset comprises measures, using Colorado State University's Ice Spectrometer (IS, an immersion freezing device with a range from 0°C down to -26 to -29°C) of atmosperic ice nucleating particle (INP) concentrations taken on ARM's Mobile Facility (AMF-1) Aerosol Observing System, near Villa Yacanto in central Argentina, during the Cloud, Aerosol, and Complex Terrain Interactions (CACTI) Experiment. A filter sampler was mounted on the AOS trailer (2 m below the AOS inlet). Single-use filter units open to the atmosphere fitted with pre-cleaned and pre-sterilized, 47-mm dia. Nuclepore polycarbonate filters were used. Filters were typically drawn for an 8-hour period, totaling 6000 liters sampled on average. After collection, filters were stored at -20°C until processed. Initial processing to obtain spectra of INP number concentration active via the immersion freezing mechanism versus temperature was conducted using CSU's IS instrument (McCluskey et al., 2018). For measurment of INPs, collected aerosol particles were re-suspended in 7-8 mL of 0.1 µm-filtered deionized (DI) water. Aliquots of each suspension, and serial dilutions, were dispensed into trays which were fit into aluminum blocks in the IS. Samples are cooled at 0.33°C min-1 and the freezing temperatures of wells recorded automatically. Cumulative INP concentrations were determined by first calculating the INPs per mL of suspension based on Vali (1971) and then converting to concentration per standard liter of air using the proportion of the total liquid sample dispensed and the air sample volumes. An aliquot of suspension fro selected samples were also heat treated (95°C for 20 min) to denature and deactivate biological INPs, and another aliquot digested in 10% H2O2 at 95°C under UV-B to remove all organic carbon INPs. McCluskey, C. S., J. Ovadnevaite, M. Rinaldi, J. Atkinson, F. Belosi, D. Ceburnis, S. Marullo, T. C. J. Hill, U. Lohmann, Z. A. Kanji, C. O’Dowd, S. M. Kreidenweis, P. J. DeMott, 2018: Marine and Terrestrial Organic Ice Nucleating Particles in Pristine Marine to Continentally-Influenced Northeast Atlantic Air Masses, Journal of Geophysical Research: Atmospheres, 123, 6196–6212, https://doi.org/10.1029/2017JD028033. Vali, G., 1971: Quantitative evaluation of experimental results on the heterogeneous freezing nucleation of supercooled liquids. J. Atmos. Sci., 28, 402–409.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Study of Stratus-Lowering Marine-Fog Events Observed During C-FOG

Two stratus lowering marine fog events observed on 28 September and 04 October 2018 during the Coastal Fog (C-Fog) field campaign that took place offshore of Eastern Canada during 1 September to 6 October 2018 are described. In-situ, profiling and remote sensing observations were made at selected land sites in eastern Newfoundland (NL) and Nova Scotia (NS) as well as aboard the research vessel (R/V) Hugh R. Sharp that cruised in adjoining coastal waters. Synoptic scale analysis showed that both fog episodes were an outcome of the interaction between synoptic-scale surface level low-pressure systems and a contiguous high-pressure system. At the same time, back trajectories revealed that the bulk of the fog layer is formed due to differential advection. Here, the diameter of the fog droplets at the surface gradually decreased from the centre of the fog layer to its leading/trailing edges. The bimodal fog droplet diameter distribution with peaks at 5-10 µm and 20-25 µm provided clues on droplet collision and coalescence processes. The observed difference between microphysical variables and droplet distribution between the two fog events and within same fog layer may have been governed by atmospheric boundary layer conditions (e.g., humidity conditions and turbulence) prevailed in the fog layer. Overall, it is concluded that the life cycle of observed stratus-lowering coastal-fog episodes is dependent on synoptic conditions as well as atmospheric boundary layer characteristics such as stability, cloud top cooling and entrainment.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

Measurements of a quantum bulk acoustic resonator using a superconducting qubit

Phonon modes at microwave frequencies can be cooled to their quantum ground state using conventional cryogenic refrigeration, providing a convenient way to study and manipulate quantum states at the single phonon level. Phonons are of particular interest because mechanical deformations can mediate interactions with a wide range of different quantum systems, including solid-state defects, superconducting qubits, and optical photons when using optomechanically active constructs. Phonons, thus, hold promise for quantum-focused applications as diverse as sensing, information processing, and communication. Here, we describe a piezoelectric quantum bulk acoustic resonator (QBAR) with a 4.88 GHz resonant frequency, which, at cryogenic temperatures, displays large electromechanical coupling strength combined with a high intrinsic mechanical quality factor, Q i ≈ 4.3 × 10 4 . Using a recently developed flip-chip technique, we couple this QBAR resonator to a superconducting qubit on a separate die and demonstrate the quantum control of the mechanics in the coupled system. Furthermore, this approach promises a facile and flexible experimental approach to quantum acoustics and hybrid quantum systems.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2020

Sensitivity of surface temperature to oceanic forcing via q-Flux Green’s function experiments. Part III: asymmetric response to warming and cooling

Climate response is often assumed to be linear in climate sensitivity studies. However, by examining the surface temperature (TS) response to pairs of oceanic forcings of equal amplitude but opposite sign in a large set of local q-flux perturbation experiments with CAM5 coupled to a slab, we find strong asymmetry in TS responses to the heating and cooling forcings, indicating a strong nonlinearity intrinsic to the climate system examined. Regardless of where the symmetric forcing is placed, the cooling response to the negative forcing always exceeds the warming to the positive forcing, implying an intrinsic inclination towards cooling of our current climate. Thus, the ongoing global warming induced by increasing greenhouse gases may have already been alleviated by the asymmetric component of the response. The common asymmetry in TS response peaks in high latitudes, especially along sea ice edges, with notable seasonal dependence. Decomposition into different radiative feedbacks through a radiative kernel indicates that the asymmetry in the TS response is realized largely through lapse rate and albedo feedbacks. Further process interference experiments disabling the seasonal cycle and/or sea ice reveal that the asymmetry originates ultimately from the presence of the sea ice component and is further amplified by the seasonal cycle. The fact that a pair of opposite tropical q-flux forcings can excite very similar asymmetric response as a pair placed at 55°S strongly suggests the asymmetric response is a manifestation of an internal mode of the climate model system.

Liu, Fukai↗
DOE OSTI2026

Ion Trapping Studies and Mitigation Strategies for the EIC ERL-Based Strong Hadron Cooler

An Energy Recovery Linac based strong hadron cooler was previously considered for the Electron-Ion Collider. The required electron beam parameters for variable-energy strong hadron cooling place significant constraints on ion trapping and collective effects. This paper presents initial studies of these constraints through a combination of analytical modelling and numerical simulations of ion production, trapping behaviour, and mitigation strategies. A multi-bunch tracking framework based on ELEGANT with the ionEffects module is used to simulate machine operation over millisecond time scales, corresponding to more than 3 × 10^5 electron bunches. The simulations include modelling of ionisation processes together with transverse electron–ion dynamics, allowing the evolution and accumulation of ions to be investigated. Analytical expressions based on Gaussian beam distributions are used to estimate ion trapping conditions and benchmark the simulation results. A bi-periodic bunch spacing scheme is also investigated as a possible mitigation method by detuning the ion oscillation frequency. These studies provide an initial assessment of ion trapping in the strong hadron cooler and demonstrate possible approaches for reducing beam–ion effects.

Bi, R. [Lancaster University, Cockcroft Institute]↗
DOE OSTI2024

3D hybrid fluid-particle jet simulations and the importance of synchrotron radiative losses

Context. Relativistic jets in active galactic nuclei are known for their exceptional energy output, and imaging the synthetic synchrotron emission of numerical jet simulations is essential for a comparison with observed jet polarization emission. Aims. Through the use of 3D hybrid fluid-particle jet simulations (with the PLUTO code), we overcome some of the commonly made assumptions in relativistic magnetohydrodynamic (RMHD) simulations by using non-thermal particle attributes to account for the resulting synchrotron radiation. Polarized radiative transfer and ray-tracing (via the RADMC-3D code) highlight the differences in total intensity maps when (i) the jet is simulated purely with the RMHD approach, (ii) a jet tracer is considered in the RMHD approach, and (iii) a hybrid fluid-particle approach is used. The resulting emission maps were compared to the example of the radio galaxy Centaurus A. Methods. We applied the Lagrangian particle module implemented in the latest version of the PLUTO code. This new module contains a state-of-the-art algorithm for modeling diffusive shock acceleration and for accounting for radiative losses in RMHD jet simulations. The module implements the physical postulates missing in RMHD jet simulations by accounting for a cooled ambient medium and strengthening the central jet emission. Results. We find a distinction between the innermost structure of the jet and the back-flowing material by mimicking the radio emission of the Seyfert II radio galaxy Centaurus A when considering an edge-brightened jet with an underlying purely toroidal magnetic field. We demonstrate the necessity of synchrotron cooling as well as the improvements gained when directly accounting for non-thermal synchrotron radiation via non-thermal particles.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2022

Analysis of predicted mean vote-based model predictive control for residential HVAC systems

Model Predictive Control (MPC) is an advanced process control method that has attracted much attention in building heating, ventilation, and air conditioning (HVAC) systems. Here, this paper analyzes the optimal precooling performance in residential buildings using MPC with two different comfort indices, namely, temperature and predicted mean vote (PMV). It first formulates, for each comfort index, an optimization problem that accounts for different factors, such as weather, home thermal condition, prediction horizon, time-of use (TOU) utility rate, and rated cooling capacity. The problem is then solved, resulting in an MPC strategy that determines the HVAC on/off control signal and minimizes energy cost over a receding time horizon while maintaining thermal comfort. The energy performance difference between temperature-based and PMV-based MPC strategies is subsequently investigated, especially in light of the interior wall surface temperature and under different combinations of the factors. Extensive simulation results demonstrated that the proposed MPC strategies are adaptive and their performances depend primarily on weather, home thermal condition, and prediction horizon, while the impact of TOU utility rate and rated cooling capacity is relatively small. Because the PMV-based MPC strategy can take advantage of the lower interior wall surface temperature due to precooling, it resulted in 8–45% cost savings for the scenarios investigated and an average increase of 0.042–0.113 in the absolute value of the PMV index compared to the temperature-based MPC strategy.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Tempering kinetics during multilayer laser additive manufacturing of a ferritic steel

Grade 91 steel forms martensite during additive manufacturing and the extent of tempering of martensite significantly affects the mechanical properties of parts. Currently, there is a lack of quantitative understanding of the tempering kinetics for Grade 91 steel, and as a result, the effects of repeated thermal cycles on properties for different processing conditions cannot be determined. Here we evaluate the tempering kinetics by determining the constant terms in the Johnson Mehl Avrami kinetic equation from the tempering data available in the literature and the thermal cycles computed using a rigorously-tested heat and fluid flow model of multi-layer additive manufacturing. The raw tempering data are cleaned using a neural network to enhance accuracy. The lower layers experience repeating cycles of heating and cooling when the upper layers are added. As a result, the hardness is reduced owing to the tempering of martensite. In contrast, martensite formed in the upper layers is not tempered to the same extent and the hardness remains high. Therefore, the hardness of the part increases with the distance from the substrate. Variations in the heat input at different laser powers and scanning speeds significantly affect the extent of tempering. Finally, since the method used here can provide a quantitative understanding of the tempering of martensite and the spatial variation in hardness, it can be used to tailor the microstructure and hardness of heat treatable printed metallic parts.

36 MATERIALS SCIENCE↗
DOE OSTI2023

SAS4A/SASSYS-1 Validation with EBR-II Tests Performed During the SHRT Testing Program (Rev. 2)

The EBR-II sodium-cooled fast reactor supported a wide range of fast reactor research activities. The final fifteen years of operations at EBR-II were used for experiments and tests to demonstrate the importance of passive safety in liquid metal reactors and the capability of such systems to provide strong passive responses during off-normal conditions. The Shutdown Heat Removal Test program at EBR-II provided test data supporting the validation of computer codes for design, licensing, and operation of LMRs, among other objectives. The program included nearly sixty tests, most of which were protected and unprotected loss of flow and loss of heat sink tests run at various initial powers and flow rates. This report documents the results of modeling and simulation of tests from the Shutdown Heat Removal Test program to support validation of Argonne’s SAS4A/SASSYS-1 fast reactor safety analysis code. SHRT-17 and SHRT-6 were protected loss of flow tests where a loss of electrical power to all sodium coolant pumps was simulated to demonstrate the effectiveness of natural circulation cooling characteristics. SHRT-45R, SHRT-39, and SHRT-43R were unprotected loss of flow tests where the control rod scram function of the plant protection system was disabled to demonstrate the effectiveness of EBR-II’s passive reactivity feedbacks. BOP-301 and BOP-302R were unprotected loss of heat sink tests that demonstrated how reactivity feedback effects driven by changes to the core inlet temperature can shut down the fission process. PICT-5/6 demonstrated how core power could be increased and decreased via changes in the intermediate sodium and feedwater flow rates. This validation activity leverages modeling and simulation efforts that originated under an International Atomic Energy Agency Coordinated Research Project for benchmark analysis of the EBR-II Shutdown Heat Removal Tests. The SAS4A/SASSYS-1 models originally developed for the CRP have been modernized to utilize new code features and modeling practices. Differences between the predicted and measured test data were explored and the causes of these differences were identified as being due to modeling approximations, uncertainty in transient component behavior, and instrumentation uncertainties. Overall, it was concluded that for all tests simulated there was good agreement between the flow, power, and temperature predictions and the measured data.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2021

Creep Behavior of Compact γ′-γ″ Coprecipitation Strengthened IN718-Variant Superalloy

The development of high-temperature heavy-duty turbine disk materials is critical for improving the overall efficiency of combined cycle power plants. An alloy development strategy to this end involves superalloys strengthened by ‘compact’ γ′-γ″ coprecipitates. Compact morphology of coprecipitates consists of a cuboidal γ′ precipitate such that γ″ discs coat its six {001} faces. The present work is an attempt to investigate the microstructure and creep behavior of a fully aged alloy exhibiting compact coprecipitates. We conducted heat treatments, detailed microstructural characterization, and creep testing at 1200 °F (649 °C) on an IN718-variant alloy. Our results indicate that aged IN718-27 samples exhibit a relatively uniform distribution of compact coprecipitates, irrespective of the cooling rate. However, the alloy ruptured at low strains during creep tests at 1200 °F (649 °C). At 100 ksi (689 MPa) load, the alloy fails around 0.1% strain, and 75 ksi (517 MPa) loading causes rupture at 0.3% strain. We also report extensive intergranular failure in all the tested samples, which is attributed to cracking along grain boundary precipitates. The results suggest that while the compact coprecipitates are indeed thermally stable during thermomechanical processing, the microstructure of the alloy needs to be optimized for better creep strength and rupture life.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Exploring Plasma Heating in the Current Sheet Region in a Three-dimensional Coronal Mass Ejection Simulation

We simulate a coronal mass ejection using a three-dimensional magnetohydrodynamic code that includes coronal heating, thermal conduction, and radiative cooling in the energy equation. The magnetic flux distribution at 1 Rs is produced by a localized subsurface dipole superimposed on a global dipole field, mimicking the presence of an active region within the global corona. Transverse electric fields are applied near the polarity inversion line to introduce a transverse magnetic field, followed by the imposition of a converging flow to form and destabilize a flux rope, producing an eruption. We examine the quantities responsible for plasma heating and cooling during the eruption, including thermal conduction, radiation, adiabatic effects, coronal heating, and ohmic heating. We find that ohmic heating is an important contributor to hot temperatures in the current sheet region early in the eruption, but in the late phase, adiabatic compression plays an important role in heating the plasma there. Thermal conduction also plays an important role in the transport of thermal energy away from the current sheet region throughout the reconnection process, producing a “thermal halo” and widening the region of high temperatures. We simulate emission from solar telescopes for this eruption and find that there is evidence for emission from heated plasma above the flare loops late in the eruption, when the adiabatic heating is the dominant heating term. These results provide an explanation for hot supra-arcade plasma sheets that are often observed in X-rays and extreme ultraviolet wavelengths during the decay phase of large flares.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2026

Implications of Sea Breeze Circulations on boundary layer aerosols in the southern coastal Texas region

The Sea Breeze Circulation (SBC) influences atmospheric processes at multiple scales in coastal regions. Understanding how SBCs impact the aerosol number budget and aerosol–cloud interaction processes is essential. This study investigates sea breeze–aerosol interactions (SAIs) during 46 summertime SBC events using data from the TRacking Aerosol Convection Interactions Experiment (TRACER) field campaign across urban (main) and rural (supplemental) coastal sites in southern Texas. Weather Research and Forecasting model coupled with Chemistry (WRF-Chem) simulations complement observations to explore spatio-temporal meteorological controls on boundary layer aerosols. During the summertime, Sea Breeze Fronts (SBF) penetrating inland transported cool, moist air over the land, introducing air masses with distinct properties compared to the preexisting continental air. These SAIs cause variability in number concentrations of up to a factor of two, with events typically lasting ∼ 5 h before returning to background conditions. SAI impact on aerosols varies with site proximity to water and the preceding sea breeze (SB) history, primarily affecting the marine-influenced accumulation mode. The main site, influenced by both Galveston Bay and the Gulf of Mexico, reflects a stronger marine influence. In contrast, a supplemental site, at a similar shoreline distance but exposed only to the Gulf of Mexico and typically upstream of the urban core, samples SB air that has traversed land and partially regained continental characteristics. Simulations show that the regional SAIs extend ∼ 50 km inland and reach up to the boundary layer height. SAIs further decrease cloud condensation nuclei relevant aerosol number concentrations in ∼ 20 % of events during SBF passage.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI1989

Nuclear Safety [Vol. 30, No. 3, July-September 1989]

Nuclear Safety is a review journal that covers significant developments in the field of nuclear safety. Its scope includes the analysis and control of hazards associated with nuclear energy, operations involving fissionable materials, and the products of nuclear fission and their effects on the environment. Primary emphasis is on safety in reactor design, construction, and operation; however, the safety aspects of the entire fuel cycle, including fuel fabrication, spent-fuel processing, nuclear waste disposal, handling of radioisotopes, and environmental effects of these operations, are also treated. Table of Contents for this issue follows. GENERAL SAFETY CONSIDERATIONS: 325 Safety of Framatome Advanced Nuclear Steam Supply Systems Designs by J. A. Charles and D. Lange, 333 Book Review of Nuclear Accidents: Intervention Levels for the Protection of the Public by H. B. Piper; ACCIDENT ANALYSIS: 335 Living PRA Computer Systems by S. C. Dinsmore and H.-P. Balfanz, 343 Summary of ICAP Assessments of RELAP5/MOD2 by W. E. Driskell and R. G. Hanson; CONTROL AND INSTRUMENTATION: 352 Thermal Performance Monitoring System at Maanshan Nuclear Power Plant by H.-J. Chao, Y.-P. Lin, G.-H. Jou, L.-Y. Liao, and Y.-B. Chen; DESIGN FEATURES: 358 Warning Systems for Nuclear Power Plant Emergencies by J. H. Sorensen and D. S. Mileti; WASTE AND SPENT FUEL MANAGEMENT: 371 Activities Related to Waste Management Compiled by E G. Silver; OPERATING EXPERIENCES: 382 Steam Generator Tube Performance: Experience with Water-Cooled Nuclear Power Reactors During 1985 by O. S. Tatone and R. L. Tapping, 400 Systems Interaction Analyses: Concepts and Techniques (Part II) by M. D. Muhlheim and G. A. Murphy, 413 Reactor Shutdown Experience Compiled by J. W. Cletcher, 416 Operating U.S. Power Reactors Compiled by E G. Silver; RECENT DEVELOPMENTS: 440 General Administrative Activities Compiled by E G. Silver, 460 Reports, Standards, and Safety Guides by D. S. Queener, 466 Status of Power-Reactor Licensing Activities Compiled by E G. Silver, 470 Proposed Rule Changes as of Mar. 31, 1989; ANNOUNCEMENTS: 334 Proceedings Published, 351 CEC Seminar on Methods and Codes for Assessing the Off-Site Consequences of Nuclear Accidents, 357 Short Course on Multiphase Flow and Heat Transfer: Bases and Applications in A: The Nuclear Power Industry B: The Process Industries, 357 International Conference on Probabilistic Safety Assessment and Management, 478 International Topical Meeting on the Safety, Status, and Future of Non-Commercial Reactors and Irradiation Facilities, 475 The Authors.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2019

Cutting edge research and new technologies in heat and mass transfer processes of refrigeration and air conditioning systems

This special edition of the Science and Technology for the Built Environment (STBE) presents eight selected articles originally presented at the 17th International Refrigeration and Air Conditioning Conference held at Purdue University, West Lafayette, IN, USA, during July 9–12, 2018. All eight articles were significantly expanded with additional technical content and received full peer review before being finally accepted for publication in this special issue of the STBE. The eight articles in this special issue cover a wide range of topics from condensation and evaporation of low global warming potential (LGWP) refrigerants to phase change material storage for personal cooling systems, from frosting on hydrophilic and hydrophobic coated surfaces to geometry optimization of heat exchanger fins. Furthermore, these articles describe cutting-edge research and feasibility studies of new technologies that were recently investigated for refrigeration and air conditioning applications.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Understanding Oxide–Metal Interactions During Hot Isostatic Pressing to Diffusion Bond Aluminum Alloy 6061 Plates

The interaction between Mg, Si, and Al 2 O 3 during hot isostatic pressing diffusion bonding of aluminum alloy 6061 (AA6061) plates was investigated through thermodynamic calculations and experimental microstructural characterization. Thermodynamic calculations as functions of temperature, pressure, and composition revealed that the interaction among Mg, Si, and Al 2 O 3 yields Mg 2 Si and either MgO + Al or MgAl 2 O 4 + Al, facilitating the reduction of Al 2 O 3 and allowing Al/Al metallic bonds to form. Total pressure variation had a negligible influence on the oxygen partial pressure, and consequently, the reaction product formation. Oxygen partial pressure variation as a function of temperature and initial amount of Al 2 O 3 determined the formation of either MgO or MgAl 2 O 4 . Experimental Hot Isostatic Pressure (HIP) bonding at 723 K and 833 K under a constant pressure of 1017 atm documented the cooling rate-dependent formation of β–Mg 2 Si precipitates. High-resolution transmission electron microscopy imaging and selected area electron diffraction patterns verified the formation of β–Mg 2 Si and MgO at the interface but did not detect MgAl 2 O 4 . In conclusion, findings from this study clarify the role of thermochemical interactions in oxide disruption and bonding mechanisms during HIP diffusion bonding of AA6061 and provide guidance for optimizing joining processes for monolithic nuclear fuel assemblies.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

On the existence of orthorhombic martensite in a near-α titanium base alloy used for additive manufacturing

Additive manufacturing is a state-of-the-art production technology to produce tailor-made and highly complex parts. Among various other alloys, Ti base alloys are frequently used in this manufacturing technique due to their well-balanced properties and their wide range of applications. Allotropic phases and the occurrence of athermal phase transformations are the main reasons why these alloys hold a great development potential and are the basis of extensive use. High cooling rates during manufacturing lead to martensitic phases and the formation of nanometer-sized microstructures resulting in extraordinary strength. Simultaneously, such high cooling rates cause a high amount of lattice defects and the occurrence of residual stresses, which finally may result in delamination effects and cracks. Usually, a common approach to reduce residual stresses during additive manufacturing is to decrease thermal gradients by increasing the heat input or preheating the building platform. Instead of applying the typical approaches to lower thermal gradients, this study deals with the origin of the ‘softer’ orthorhombic martensite by accelerating the solidification process. The implementation of the orthorhombic phase in bulk components was inspired by a new phase transformation herein reported for the first time in the powder material, which also validates the possible occurrence of two martensitic phases in the same alloy. Various sophisticated characterization techniques like high energy and high-temperature X-ray diffraction, high-resolution transmission electron microscopy as well as atom probe tomography were applied to characterize this softer orthorhombic martensitic phase in detail aiming to highlight the opportunities accompanied by this new approach for additive manufacturing of titanium alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Evolution of dislocations during the rapid solidification in additive manufacturing

Materials processed by fusion-based additive manufacturing (AM) typically exhibit relatively high dislocation densities, along with cellular structures and elemental segregation. This representative structural feature significantly influences material performance; however, post-mortem microstructure characterizations of AM materials cannot capture the dynamic evolution of dislocations during the manufacturing process, thereby offering limited mechanism-based guidance for further advancing AM techniques and facilitating the qualification and certification of AM products. In this study, we conduct operando high-energy synchrotron X-ray diffraction experiments on wire-laser directed energy deposition of 316 L stainless steel. Through a unique configuration, our operando synchrotron experiments semi-quantitatively probe the dislocation density in solid phases and their dynamic changes during solidification and subsequent cooling. By integrating this advanced synchrotron technique with multi-physics simulation, in-situ neutron diffraction, and multi-scale electron microscopy characterization, our mechanistic study aims to elucidate the effects of rapid cooling and subsequent thermal cycling on the dislocation generation and evolution.

36 MATERIALS SCIENCE↗