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At least 1,243 records · Page 69

Investigation of laser direct energy deposition for production of ODS alloys

Laser blown powder additive manufacturing (AM) was performed to evaluate the feasibility of using the technique to fabricate oxide dispersion strengthened (ODS) alloys. The idea was to utilize an in-situ oxidation reaction to oxidize reactive elements to generate a refined dispersion of the dispersoids with a uniform size distribution. Builds were fabricated using Y added 316L in a reactive atmosphere and an inert atmosphere for comparisons. Detailed characterization was performed to understand the as-fabricated microstructure. Detailed characterization and chemical analysis show that there is significant Y loss during deposition. The loss in Y during processing leads to a reduced volume fraction of precipitates (~2 x 10 18 /m 3 ) with an average size of ~97 nm. Mechanical testing of the samples fabricated in both air and in inert atmosphere were performed at RT, 200 °C, 400 °C and 600 °C. The mechanical properties were then compared with austenitic ODS alloys that were reported in the literature. The results show that while the ultimate tensile strengths were comparable with wrought ODS alloys, the deterioration in yield strength with temperature was more severe in the case of the AM fabricated ODS material. However, the ductility was observed to be higher than all wrought 316L ODS alloys. Future efforts will focus on increasing the percentage of Y in the pre-alloyed powder to refine the dispersoids. In addition, a close control of process parameters and post processing treatments need to be explored to optimize the dispersoids volume fraction.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

MC2-3 / DIF3D Analysis for the ZPPR-15 Doppler and Sodium Void Worth Measurements

This manuscript covers validation efforts for our deterministic codes at Argonne National Laboratory. The experimental results come from the ZPPR-15 work in 1985-1986 which was focused on the accuracy of physics data for the integral fast reactor concept. Results for six loadings are studied in this document and focus on Doppler sample worths and sodium void worths. The ZPPR-15 loadings are modeled using the MC2-3/DIF3D codes developed and maintained at ANL and the MCNP code from LANL. The deterministic models are generated by processing the as-built geometry information, i.e. MCNP input, and generating MC2-3 cross section generation instructions and a drawer homogenized equivalence problem. The Doppler reactivity worth measurements are small heated samples which insert very small amounts of reactivity into the system (< 2 pcm). The results generated by the MC2-3/DIF3D codes were excellent for ZPPR-15A and ZPPR-15B and good for ZPPR-15D, compared to the MCNP solutions. In all cases, notable improvements were made over the analysis techniques applied to the same problems in 1987. The sodium void worths from MC2-3/DIF3D were quite good at 37.5 pcm while MCNP result was 33 pcm and the measured result was 31.5 pcm. Copyright © (2015) by the American Nuclear Society All rights reserved.

Smith, Micheal A.↗

Processing and properties of a solid energy fuel from municipal solid waste (MSW) and recycled plastics

Highlights: • Briquetting was used to produce solid fuels from municipal solid waste and recycled plastics. • Optimal drying, processing temperature and pressure were found to produce stable briquettes. • Addition of waste plastics yielded heating values comparable with typical coal feedstocks. • This processing method improves utilization of paper and plastic diverted from landfills. - Abstract: Diversion of waste streams such as plastics, woods, papers and other solid trash from municipal landfills and extraction of useful materials from landfills is an area of increasing interest especially in densely populated areas. One promising technology for recycling municipal solid waste (MSW) is to burn the high-energy-content components in standard coal power plant. This research aims to reform wastes into briquettes that are compatible with typical coal combustion processes. In order to comply with the standards of coal-fired power plants, the feedstock must be mechanically robust, free of hazardous contaminants, and moisture resistant, while retaining high fuel value. This study aims to investigate the effects of processing conditions and added recyclable plastics on the properties of MSW solid fuels. A well-sorted waste stream high in paper and fiber content was combined with controlled levels of recyclable plastics PE, PP, PET and PS and formed into briquettes using a compression molding technique. The effect of added plastics and moisture content on binding attraction and energy efficiency were investigated. The stability of the briquettes to moisture exposure, the fuel composition by proximate analysis, briquette mechanical strength, and burning efficiency were evaluated. It was found that high processing temperature ensures better properties of the product addition of milled mixed plastic waste leads to better encapsulation as well as to greater calorific value. Also some moisture removal (but not complete) improves the compacting process and results in higher heating value. Analysis of the post-processing water uptake and compressive strength showed a correlation between density and stability to both mechanical stress and humid environment. Proximate analysis indicated heating values comparable to coal. The results showed that mechanical and moisture uptake stability were improved when the moisture and air contents were optimized. Moreover, the briquette sample composition was similar to biomass fuels but had significant advantages due to addition of waste plastics that have high energy content compared to other waste types. Addition of PP and HDPE presented better benefits than addition of PET due to lower softening temperature and lower oxygen content. It should be noted that while harmful emissions such as dioxins, furans and mercury can result from burning plastics, WTE facilities have been able to control these emissions to meet US EPA standards. This research provides a drop-in coal replacement that reduces demand on landfill space and replaces a significant fraction of fossil-derived fuel with a renewable alternative.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Solute Redistribution During Aging in a Laser-Based Powder Bed Fusion-Produced Fe-18Ni-9Co-5Mo-Ti Maraging Steel

Solute distribution during the laser-based powder bed fusion of metals process is highly complex because of solidification. This study builds on a previous investigation of how solute heterogeneities across different scales influence phase distribution and aging physical phenomena in a Fe-18Ni-9Co-5Mo-Ti maraging steel (Santana et al. in Addit Manuf 104494, 2024). Previous work using energy-dispersive X-ray spectroscopy revealed heterogeneous Ni and Mo enrichment at intercellular regions. Using X-ray diffraction, 8 ± 3% retained austenite was quantified in as-built samples. Additionally, electron backscatter diffraction analysis exposed the location of retained austenite along cell boundaries. In this work, scanning transmission electron microscopy results revealed the presence of non-enriched retained austenite in the as-built condition. With increased aging temperature, Ni and Mo enrichment in austenite increased, especially at the austenite/martensite boundary. Solute diffusion was simulated in DICTRA Thermo-Calc® software to assess solute redistribution between the matrix and second phases and to comprehend whether elemental diffusion processes are interconnected. Three different scenarios were considered: (1) solute diffusion in the matrix; (2) diffusion with enriched austenite in the intercellular region; (3) diffusion with non-enriched austenite in the intercellular region. Results showed that Ni partitioning controls austenite growth and that boundary regions exhibit higher element enrichment than the core.

42 ENGINEERING↗

Analysis of Niobium Electropolishing Using a Generalized Distribution of Relaxation Times Method

Using electrochemical impedance spectroscopy, we have devised a method of sensing the microscopic surface conditions on the surface of niobium as it is undergoing an electrochemical polishing (EP) treatment. The method uses electrochemical impedance spectroscopy (EIS) to gather information on the surface state of the electrode without disrupting the polishing reaction. The EIS data is analyzed using a so-called distribution of relaxation times (DRT) method. Using DRT, the EIS data can be deconvolved into discrete relaxation time peaks without any a priori knowledge of the electrode dynamics. By analyzing the relaxation time peaks, we are able to distinguish two distinct modes of the EP reaction. As the polishing voltage is increased, the electrode transitions from the low voltage EP mode, characterized by a single relaxation time peaks, to the high voltage EP mode, characterized by two relaxation time peaks. We theorize that this second peak is caused by the formation of an oxide layer on the electrode. We also find that this oxide induced peak transitions from to a negative relaxation time, which is indicative of a blocking electrode process. By analyzing EPed samples, we show that samples polished in the low voltage mode have significantly higher surface roughness due to grain etching and faceting. We find that the surface roughness of the samples only improves when the oxide film peak is present and in the negative relaxation time region. This shows that EIS combined with DRT analysis can be used to predict etching on EPed Nb. This method can also be performed before or during the EP, which could allow for adjustment of polishing parameters to guarantee a smooth cavity surface finish.

43 PARTICLE ACCELERATORS↗

Optimal reference genes for RNA tissue analysis in small animal models of hemorrhagic fever viruses

Abstract Reverse-transcription quantitative polymerase chain reaction assays are frequently used to evaluate gene expression in animal model studies. Data analyses depend on normalization using a suitable reference gene (RG) to minimize effects of variation due to sample collection, sample processing, or experimental set-up. Here, we investigated the suitability of nine potential RGs in laboratory animals commonly used to study viral hemorrhagic fever infection. Using tissues (liver, spleen, gonad [ovary or testis], kidney, heart, lung, eye, brain, and blood) collected from naïve animals and those infected with Crimean–Congo hemorrhagic fever (mice), Nipah (hamsters), or Lassa (guinea pigs) viruses, optimal species-specific RGs were identified based on five web-based algorithms to assess RG stability. Notably, the Ppia RG demonstrated stability across all rodent tissues tested. Optimal RG pairs that include Ppia were determined for each rodent species ( Ppia and Gusb for mice; Ppia and Hrpt for hamsters; and Ppia and Gapdh for guinea pigs). These RG pair assays were multiplexed with viral targets to improve assay turnaround time and economize sample usage. Finally, a pan-rodent Ppia assay capable of detecting Ppia across multiple rodent species was developed and successfully used in ecological investigations of field-caught rodents, further supporting its pan-species utility.

Davies, Katherine A.↗

Analysis of differential scanning calorimetry data for aged plutonium

Differential scanning calorimetry data for samples of a 52 year old plutonium alloy with 3.3 at. % Ga that were heated beyond the melting point is analyzed using transition state theory to find activation energies for the δ to ε and ε to liquid phase transitions. A Bayesian statistical method involving a Gaussian process model is used to find mean values and confidence intervals for the activation energies. The activation energy for the δ to ε phase transition increases by 3.3 ± 3.8% per decade, relative to the case when all age related plutonium lattice point defects have been removed through annealing. The corresponding increase in activation energy for the ε to liquid transition is shown to be 7.1 ± 1.8% per decade. It is postulated that the change in activation energy with age for both phase transitions is caused, in part, by the accumulation of the same type of lattice point defects associated with the observed increase in elastic bulk modulus over time.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Clean Energy in City Codes: A Baseline Analysis of Municipal Codification across the United States

Municipal governments in the United States are well positioned to influence clean energy (energy efficiency and alternative energy) and transportation technology and strategy implementation within their jurisdictions through planning, programs, and codification. Municipal governments are leveraging planning processes and programs to shape their energy futures. There is limited understanding in the literature related to codification, the primary way that municipal governments enact enforceable policies. The authors fill the gap in the literature by documenting the status of municipal codification of clean energy and transportation across the United States. More directly, we leverage online databases of municipal codes to develop national and state-specific representative samples of municipal governments by population size. Our analysis finds that municipal governments with the authority to set residential building energy codes within their jurisdictions frequently do so. In some cases, communities set codes higher than their respective state governments. Examination of codes across the nation indicates that municipal governments are employing their code as a policy mechanism to address clean energy and transportation.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Roll-to-roll production of catalyst coated membranes for low-temperature electrolyzers

Here we demonstrate a roll-to-roll (R2R) process for direct coating of anode catalyst layers on a polymer electrolyte membrane for low-temperature water electrolysis. To develop this process, we studied catalyst ink formulation, ink-membrane interactions, and coating quality. The catalyst inks were a mixture of iridium oxide (IrO2) and Nafion in a water and alcohol dispersion medium. The type of alcohol (methanol, ethanol, propanols) and water-to-alcohol ratio were varied to determine their influence on membrane swelling, dispersion quality, and coatability. Interactions of the ink dispersion medium with the membrane were characterized using sessile-drop contact-angle measurements. These measurements show that the ratio of water to alcohol has a strong influence on how rapidly the dispersion media is absorbed by the membrane. Rheology of the catalyst inks was measured to understand the microstructure of the catalyst particles in the ink. This analysis found that 1-propanol leads to better dispersion of the IrO2 particles than ethanol. Small-scale coating samples were prepared to understand coating uniformity and formation of irregularities. Subsequently, two water/1-propanol ratios (90:10 and 75:25) were down-selected for large-scale R2R slot die coating. The R2R catalyst-coated membrane (CCM) coating process increased catalyst layer production throughput by over 500x compared to our standard lab-scale spray coating. The CCMs obtained from this process were tested as single-cell membrane electrode assemblies. They exhibited a cell voltage of 1.91 V at a current density of 2 A/cm2, which is comparable to spray-coated CCMs. In conclusion, the work presented here demonstrates a continuous, scalable manufacturing process that eliminates the need for the decal transfer step typically used in CCM production.

42 ENGINEERING↗

Conversion of CO 2 into Commercial Materials Using Carbon Feedstocks

In this project, our research focused on developing reaction chemistry that would support using carbon as a reductant for CO 2 utilization that would permit CO 2 consumption on a scale that would match or exceed anthropomorphic CO 2 generation for energy production from fossil fuels. Armed with the knowledge that reactions attempting to produce compounds with an energy content greater than CO 2 would be thermodynamically challenged and/or require significant amounts of energy, we developed a potential process that utilized a solid carbon source and recycled the carbon to effectively provide infinite time for the carbon to react. During testing of different carbon sources, we found a wide range of reaction rates. Biomass-derived samples had the most reactivity and coals and petcoke had the lowest. Because we had anticipated this challenge, we recognized that a catalyst would be necessary to improve reaction rates and conversion. From the data analysis of carbon samples, we recognized that alkali metals improved the reaction rate. Through parametric testing of catalyst formulations we were able to increase the reaction rate with petcoke by a factor of >70. Our efforts to identify the reaction mechanism to assist in improving the catalyst formulation demonstrated that the catalyst was catalyzing the extraction of oxygen from CO 2 and using this extracted oxygen to oxidize carbon. This was a significant discovery in that if we could modify the catalyst formulation to permit controlled the oxidation, we would have a very power selective oxidation process. With selective oxidation, CO 2 utilization could be effective used as one of the process steps in making many of the large volume commodity chemicals that support our modern lifestyles. The key challenges for incorporating these functionalities into the catalyst formulation were to make the oxidation selective and lower the temperature required for catalytic activity. We identified four catalyst families that had the potential to meet these challenges. Initial screening of the catalyst families did show that the reduction/oxidation activity did occur at lower temperatures and that these catalysts were able to cause carbon chain growth as well as C—C cleavage. A preliminary techno-economic feasibility of using petcoke/catalyst to produce a CO-rich syngas product was completed and showed significant economic promise. Testing of the different catalyst families demonstrated that Catalyst A was able to stably produce 5 sccm of ethylene/gram of catalyst at 900°C for one hour. For dry methane reforming, our Catalyst 4 was able to achieve production rates of > 10 sccm of CO and > 3 sccm of H2 per gram of catalyst at 600°C and 350 psig. Based on these developments, the potential for CO 2 utilization in the production of large volume commodity chemicals is very promising.

10 SYNTHETIC FUELS↗

Updated Radiological Inventory of G1 Reactor Thanks to a Strengthened Data Processing - 17271

The radiological inventory of G1 reactor is under refinement and consolidation. This reactor, located at the CEA Marcoule center in France, presents an issue for Chlorine-36 as graphite was used as moderator. The improvement of the 3D physical description and a better understanding of historical events enable the computation of activation levels thanks to a numerical model. These results are compared to old samples and more recent ones to quantify nuclide activity levels as well as their spatial distributions. In particular a spatial and statistical correction of sample bias leads to an update of the radiological inventory with an expected reduction of average activity levels. Another part of the work consists in identifying missing pieces of information and still uncertain parts of the reactor (sample analysis of activated concrete for instance) to reinforce the radiological inventory of G1 reactor. This will be the basis of future investigation works. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Artifact identification in X-ray diffraction data using machine learning methods

In situ synchrotron high-energy X-ray powder diffraction (XRD) is highly utilized by researchers to analyze the crystallographic structures of materials in functional devices ( e.g. battery materials) or in complex sample environments ( e.g. diamond anvil cells or syntheses reactors). An atomic structure of a material can be identified by its diffraction pattern along with a detailed analysis of the Rietveld refinement which yields rich information on the structure and the material, such as crystallite size, microstrain and defects. For in situ experiments, a series of XRD images is usually collected on the same sample under different conditions ( e.g. adiabatic conditions) yielding different states of matter, or is simply collected continuously as a function of time to track the change of a sample during a chemical or physical process. In situ experiments are usually performed with area detectors and collect images composed of diffraction patterns. For an ideal powder, the diffraction pattern should be a series of concentric Debye–Scherrer rings with evenly distributed intensities in each ring. For a realistic sample, one may observe different characteristics other than the typical ring pattern, such as textures or preferred orientations and single-crystal diffraction spots. Textures or preferred orientations usually have several parts of a ring that are more intense than the rest, whereas single-crystal diffraction spots are localized intense spots owing to diffraction of large crystals, typically >10 µm. In this work, an investigation of machine learning methods is presented for fast and reliable identification and separation of the single-crystal diffraction spots in XRD images. The exclusion of artifacts during an XRD image integration process allows a precise analysis of the powder diffraction rings of interest. When it is trained with small subsets of highly diverse datasets, the gradient boosting method can consistently produce high-accuracy results. The method dramatically decreases the amount of time spent identifying and separating single-crystal diffraction spots in comparison with the conventional method.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

Review: Recent advances of ToF-SIMS for environmental analysis and imaging

Background: Time-of-flight secondary ion mass spectrometry (ToF-SIMS) is a powerful surface analysis technique, initially developed and applied in inorganic materials and semiconductors. In past decades, ToF-SIMS has attracted more attention in its analysis capabilities of organic materials, with increased applications in biology, medical, and health development. It has also become a versatile and effective tool in environmental analysis due to its high mass resolution, mass accuracy, and depth profiling. Results: In this review, we first give an overview of the principle of ToF-SIMS and follow with recent ToF-SIMS applications in exemplary environmental study cases, including atmospheric aerosol, soil, water, plant, and organic solvent analysis. Moreover, sample preparation techniques are summarized in relation to corresponding environmental applications. Specifically, we call attention to ToF-SIMS investigations showcasing studies in surface chemical compositions, images, and depth profile analysis. These findings emphasize the important role of interfacial chemistry in environmental processes and provide valuable insights into dynamic processes, such as chemical transformation, particle formation, plant biology, and microbial inspired biotechnology development. The mass spectral imaging results acquired by ToF-SIMS offer a deeper understanding of intermediate stages and transient phases for environmental specimens. Significance: In situ and operando imaging offer new possibilities in studying phenomena in real time with high spatial resolution. Furthermore, it is anticipated that more research groups will use ToF-SIMS in environmental research given recent advances in measurement capabilities and surging needs in chemical mapping of complex analytes and systems.

Aerosol↗

Influence of thermal treatment time on structural and physical properties of polyimide films at beginning of carbonization

Poly(4,4'-oxydiphenylene-oxydiphthalimide) (POO) was thermally treated at 773 K for 1, 15 and 60 min under argon atmosphere resulting in free-standing films with intermingled characteristics between polymer and carbon-rich derivatives. Degradative thermal analysis performed by pyrolysis-gas chromatography/mass spectroscopy (Py-GC/MS) revealed CO 2 among the major products of thermal decomposition which according to electron paramagnetic resonance (EPR) passed through a radical process. X-ray diffraction (XRD) revealed thermal treated samples with semicrystalline organization that was attributed to the development of lamellae structure. Moreover, Atomic force microscopy (AFM) showed an increase in the roughness of the samples that acquired pronounced roughcast-like surface. Hence, there was an enhancement of mechanical strength and dielectric permittivity. From the data collected a mechanism of thermal decomposition was proposed.

36 MATERIALS SCIENCE↗

Evaluation of Methods for Causal Discovery in Hydrometeorological Systems

Understanding causal relations is of utmost importance in hydrology and climate research for systems identification, prediction, and understanding systems behavior in a changing climate. Traditionally, researchers in hydrometeorology attempted to study causal questions by conducting controlled experiments using numerical models. This approach, however, in most cases of interest provides uncertain results because the models are approximate representation of the natural system. An alternative approach that has recently drawn significant attention in several fields is to infer causal relations from purely observational data. It possesses several traits to its utility particularly in hydrometeorology due to the rapid accumulation of in situ and remotely sensed data records. The first objective of this study is to present a brief description of four causal discovery methods (Granger causality, Transfer Entropy, graph-based algorithms, and Convergent Cross Mapping) with special emphasis on the assumptions on which they are built. Second, using synthetic data generated from a hydrological model, we assess their performance in retrieving causal information taking into account sensitivity to sample size and presence of noise. Last, we use causal analysis to examine and formulate hypotheses on causal drivers of evapotranspiration in a shrubland region during summer and winter seasons. An interpretation of the hypotheses based on canopy seasonal dynamics and evapotranspiration processes is presented. It is hoped that the results presented here can be useful in guiding researchers studying hydrometeorological systems as to which causal method is most appropriate to the characteristics of the system under study.

54 ENVIRONMENTAL SCIENCES↗

ON THE DISCREPANCY BETWEEN THEORETICAL AND X-RAY CONCENTRATION-MASS RELATIONS FOR GALAXY CLUSTERS

In the past 15 years, the concentration-mass relation has been investigated diffusely in theoretical studies. On the other hand, only recently has this relation been derived from X-ray observations. When that happened, the results caused a certain level of concern: the X-ray normalizations and slopes were found significantly dissimilar from those predicted by theory. We analyzed 52 galaxy clusters and groups, simulated with different descriptions of the physical processes that affect the baryonic component, with the purpose of determining whether these discrepancies are real or induced by biases in the computation of the concentration parameter or in the determination of the selection function of the cluster sample for which the analysis is carried out. In particular, we investigate how the simulated concentration-mass relation depends (1) on the radial range used to derive the concentration; (2) on the presence of baryons in the simulations, and on the effect of star formation and feedback from supernovae and active galactic nuclei (AGNs). Finally, we evaluate (3) how the results differ when adopting an X-ray approach for the analysis and (4) how the selection function based on X-ray luminosity can impact the results. All effects studied go in the direction of alleviating the discrepancy between observations and simulations, although with different significance: while the choice of the radial range to fit the profiles and the inclusion of the baryonic component play only a minor role, the X-ray approach to reconstruct the mass profiles and the selection of the cluster sample have a strong impact on the resulting concentration-mass relation. Extending the fit to the most central regions or reducing the fitting radius from the virial boundary to the typical X-ray external radius causes an increase of the normalization in radiative simulations by 5%-10%. In the second case, we measure a slope that is up to twice steeper than that derived by using the typical theoretical radial range. Radiative simulations including only supernova feedback produce 30% higher concentrations than the dark matter case. Such a difference is largely reduced when including the effect of AGN feedback. The concentration-mass relation derived from the X-ray synthetic catalog is significantly steeper due to the combination of several different effects, such as environment, dynamical state and dynamical history of the clusters, bias in mass and temperature measurements, and their dependence on the radius and on the mass of the system. Finally, selecting clusters according to their X-ray luminosity produces a net increase in both normalization and slope of the relation, since at fixed mass, the most luminous clusters are also the most concentrated.

79 ASTRONOMY AND ASTROPHYSICS↗

Accelerating cosmological inference with Gaussian processes and neural networks – an application to LSST Y1 weak lensing and galaxy clustering

ABSTRACT Studying the impact of systematic effects, optimizing survey strategies, assessing tensions between different probes and exploring synergies of different data sets require a large number of simulated likelihood analyses, each of which cost thousands of CPU hours. In this paper, we present a method to accelerate cosmological inference using emulators based on Gaussian process regression and neural networks. We iteratively acquire training samples in regions of high posterior probability which enables accurate emulation of data vectors even in high dimensional parameter spaces. We showcase the performance of our emulator with a simulated 3×2 point analysis of LSST-Y1 with realistic theoretical and systematics modelling. We show that our emulator leads to high-fidelity posterior contours, with an order of magnitude speed-up. Most importantly, the trained emulator can be re-used for extremely fast impact and optimization studies. We demonstrate this feature by studying baryonic physics effects in LSST-Y1 3×2 point analyses where each one of our MCMC runs takes approximately 5 min. This technique enables future cosmological analyses to map out the science return as a function of analysis choices and survey strategy.

Astronomy & Astrophysics↗

Mechanistic Insights Into Fatigue Life Enhancement of High‐Strength Steel via Ultrasonic Impact Treatment

In this work we explore the impact of Ultrasonic Impact Treatment (UIT) on the fatigue performance of high‐strength microalloyed steel commonly used in crankshaft applications. Building on prior observations of fatigue life improvement with UIT, this work focuses on unraveling the process–structure–performance relationships underpinning these enhancements. Microstructural analysis revealed significant grain refinement in the near‐surface layers, with deformation depth increasing at higher impact energies. This led to increased surface hardness and the development of deeper compressive residual stresses, particularly in samples treated with higher impact energy. Rotating bending fatigue testing showed a substantial improvement in fatigue life for UIT‐treated samples, with the endurance limit nearly doubling compared with untreated specimens. Fractographic analysis revealed a transition in crack initiation from surface defects in untreated samples to interior regions in UIT‐treated samples, characterized by the formation of noninclusion‐induced granular bright facets (GBFs). The observed fatigue enhancement is attributed to the synergistic effects of strain hardening and compressive residual stresses, which increase the surface crack threshold and promote interior crack initiation. This study provides new mechanistic insight into UIT‐induced fatigue resistance and interior failure behavior in high‐strength steels.

36 MATERIALS SCIENCE↗