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DOE OSTI2026

Directed energy deposition of Haynes 282 nickel superalloy

Laser powder directed energy deposition was employed to fabricate Haynes® 282 Ni-based superalloy for high temperature creep testing. Material was heat treated using a single-step aging heat treatment of 800 °C for 4 h. Microstructural analysis was conducted in the as-deposited, solution-annealed, and age-hardened conditions. γ′ precipitates were absent in the as-deposited and annealed condition but formed during aging with an average size of 48.5 ± 12 nm. γ’ denuded zones ranging in thickness from 73 to 469 nm were observed adjacent to an effectively continuous grain boundary carbide film that covered 72.5% of the measured boundary length. The heat-treated material contained a high-volume fraction of TiC carbides ranging in size from 38 to 457 nm. Electron backscatter diffraction showed partial recrystallization, with 77-83% recrystallized area and a heterogeneous grain-size distribution. Creep testing at 750 °C at 300, 320, and 350 MPa revealed significantly inferior performance compared to wrought material, with higher strain rates, earlier tertiary onset, and shorter rupture lives. Fractography shows that failure was dominated by intergranular rupture. Post rupture microstructural analysis results suggest that the creep behavior was primarily governed by the non-equilibrium interface network rather than the bulk γ/γ’ matrix. In conclusion, the findings indicate that achieving wrought-like creep performance necessitates substantial improvements in the additive process, specifically focusing on enhanced homogenization, full recrystallization, and precise control over the morphology and distribution of carbides.

36 - MATERIALS SCIENCE↗

DOE OSTI2026

High-temperature mechanical properties of a γ′-strengthened Co-based superalloy designed for additive manufacturing

GammaPrint®-700 is a recently developed high γ′ (∼70% volume fraction) CoNi-based superalloy designed to combine high-temperature mechanical performance with laser powder bed fusion processability. Room-temperature yield strength ranged from 610 to 658 MPa and increased to 661 MPa (longitudinal) and 730 MPa (transverse) at 760 °C. The creep behavior compared favorably to high-γ′ Ni-based superalloys manufactured via laser powder bed fusion such as Incoloy® 939 and Inconel® 738LC. In-situ neutron diffraction data measured during creep revealed that plastic deformation was largely localized to the γ phase at 760 °C, allowing the γ’ phase to elastically compensate and maintain creep strain resistance. Furthermore, at 900 °C, this load sharing behavior was weakened, contributing to accelerated creep rate and rupture.

Creep↗

DOE OSTI2016

A horizontal vane radiometer: Experiment, theory, and simulation

The existence of two motive forces on a Crookes radiometer has complicated the investigation of either force independently. The thermal creep shear force in particular has been subject to differing interpretations of the direction in which it acts and its order of magnitude. In this article, we provide a horizontal vane radiometer design which isolates the thermal creep shear force. The horizontal vane radiometer is explored through experiment, kinetic theory, and the Direct Simulation Monte Carlo (DSMC) method. The qualitative agreement between the three methods of investigation is good except for a dependence of the force on the width of the vane even when the temperature gradient is narrower than the vane which is present in the DSMC method results but not in the theory. The experimental results qualitatively resemble the theory in this regard. The quantitative agreement between the three methods of investigation is better than an order of magnitude in the cases examined. The theory is closer to the experimental values for narrow vanes and the simulations are closer to the experimental values for the wide vanes. We find that the thermal creep force acts from the hot side to the cold side of the vane. We also find the peak in the radiometer’s angular speed as a function of pressure is explained as much by the behavior of the drag force as by the behavior of the thermal creep force.

42 ENGINEERING↗

DOE OSTI2015

Enhancement of the critical current density by increasing the collective pinning energy in heavy ion irradiated Co-doped BaFe 2 As 2 single crystals

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superconductivity, vortex matter, iron-arsenide su↗

DOE OSTI2012

Linear variable differential transformer (LVDT)-based elongation measurements in Advanced Test Reactor high temperature irradiation testing

New materials are being considered for fuel, cladding and structures in next generation and existing nuclear reactors. These materials can undergo significant dimensional and physical changes during high temperature irradiations. Currently, such changes are determined by repeatedly irradiating a specimen for a specified period of time in the Advanced Test Reactor (ATR) and then removing it from the reactor for evaluation. The labor and time to remove, examine and return irradiated samples for each measurement make this approach very expensive. In addition, such techniques provide limited data and may disturb the phenomena of interest. To resolve these issues, an instrumented creep testing capability is being developed for specimens irradiated under pressurized water reactor coolant conditions in the ATR at the Idaho National Laboratory (INL). This paper reports the status of INL efforts to develop this testing capability. In addition to providing an overview of in-pile creep test capabilities available at other test reactors, this paper focuses on efforts to design and evaluate a prototype test rig in an autoclave at INL’s High Temperature Test Laboratory.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2015

Progress Towards Prognostic Health Management of Passive Components in Advanced Reactors – Model Selection and Evaluation

This paper presents recent progress towards developing a prognostic health management framework for passive components of advanced reactors (AR). The focus of this paper is on lifecycle prognostics for passive components using a Bayesian prognostic algorithm that provides a natural framework for incorporating different sources of variability, and uncertainties inherent in the operations of AR. High-temperature creep damage, a prototypic failure mechanism in AR materials, is used as the context for this research. A Bayesian model selection approach is implemented to select the appropriate creep degradation model at any given time, using relevant sensor measurements reflecting the material degradation state. The model selection approach, based on reversible jump Markov chain Monte Carlo methods, is integrated with Bayesian particle filter-based prognostic framework. The proposed approach is evaluated using strain measurements obtained from accelerated creep testing of stainless steel specimens. Results indicate feasibility of the proposed approach in accurately identifying the creep degradation stage from the available measurements at a given time. Effect of uncertainties in material degradation model and measurement noise on the performance of the prognostic algorithm is also investigated.

advanced reactor prognostics↗

DOE OSTI2022

Novel Tube Design for Superheater Heat Exchanger Enabled Via Additive Manufacturing

Superheater tubes are critical boiler components that operate at relatively higher temperatures and pressure. Amongst the primary concerns for these tubes is the deposition of ash particles on the tube surface, leading to the reduced thickness of the tube due to material corrosion, consequently causing early creep failure of the component. In this research, a novel tube design has been proposed which resembles a teardrop or ogive shape to reduce the drag and concurrently improve the creep life of the superheater tubes. To administer the practicality of novel tubes, metal additive manufacturing (AM), for instance, laser-powder bed fusion (L-PBF), has been proposed. These unconventional designs were assessed and compared with the baseline circular tube design for mechanical design requirements (hoop stress and creep life) and the particle and flue gas flow characteristics around the differently shaped tubes. A thermomechanical finite element (FE) analysis was performed for hoop stress calculations. This study also emphasizes on effect of circumferential thermal variation on hoop stress distribution in tubes. Therefore, a detailed two-dimensional (2D) thermal simulation has been performed to report the circumferential thermal variation on the tube. A computational fluid dynamics (CFD) analysis coupled with particle tracing was performed for gas flow visualization and particle tracing around the proposed shapes and baseline circular-shaped tube design. The Schlieren optic setup was built and leveraged for qualitative validation of the proposed design. The complete design methodology established in the paper shows teardrop-shaped tubes better in terms of drag and creep life in contrast to the circular-shaped tube.

42 ENGINEERING↗

DOE OSTI2024

Design by analysis rules for ASME Section III, Division 5, Class B components

The current rules for elevated temperature ASME Section III, Division 5, Class B components, other than piping, were basically adapted from the Design-by-Rule approach for Section VIII, Division 1 vessels. A goal of the proposed new rules is to explicitly account for the design life and cyclic service while recognizing the less-rigorous requirements commensurate with lesser safety consideration. Further goals are to maximize the use of modern computational technology, for example finite element analysis in conjunction with reference stress concepts, and to avoid the need for stress classification. This paper summarizes the work done to address these issues. A summary of the design-by-analysis for primary loads, strain limit evaluation, and creep-fatigue damage assessment is presented. The proposed design-by-analysis creep-fatigue damage calculation approach uses a new elastic follow-up-based Isochronous Stress Strain Curve stress relaxation procedure. A set of sample problems are selected to validate the proposed design-by-analysis rules for creep-fatigue damage assessment. The proposed Class B rules are evaluated against the Class A elastic design rules and the experimental data obtained from a family of a simplified model test-based key-feature test results. The proposed Class B creep-fatigue damage assessment methodology yields conservative design cycles estimates compared to the experimental results.

36 MATERIALS SCIENCE↗

DOE OSTI2014

Understanding Fundamental Material Degradation Processes in High Temperature Aggressive Chemomechanical Environments

The objective of this project is to develop a fundamental understanding of the mechanisms that limit materials durability for very high-temperature applications. Current design limitations are based on material strength and corrosion resistance. This project will characterize the interactions of high-temperature creep, fatigue, and environmental attack in structural metallic alloys of interest for the very high-temperature gas-cooled reactor (VHTR) or Next–Generation Nuclear Plant (NGNP) and for the associated thermo-chemical processing systems for hydrogen generation. Each of these degradation processes presents a major materials design challenge on its own, but in combination, they can act synergistically to rapidly degrade materials and limit component lives. This research and development effort will provide experimental results to characterize creep-fatigue-environment interactions and develop predictive models to define operation limits for high-temperature structural material applications. Researchers will study individually and in combination creep-fatigue-environmental attack processes in Alloys 617, 230, and 800H, as well as in an advanced Ni-Cr oxide dispersion strengthened steel (ODS) system. For comparison, the study will also examine basic degradation processes in nichrome (Ni-20Cr), which is a basis for most high-temperature structural materials, as well as many of the superalloys. These materials are selected to represent primary candidate alloys, one advanced developmental alloy that may have superior high-temperature durability, and one model system on which basic performance and modeling efforts can be based. The research program is presented in four parts, which all complement each other. The first three are primarily experimental in nature, and the last will tie the work together in a coordinated modeling effort. The sections are (1) dynamic creep-fatigue-environment process, (2) subcritical crack processes, (3) dynamic corrosion – crack initiation processes, and (4) modeling.

36 MATERIALS SCIENCE↗

DOE OSTI2016

Progress Report on Alloy 617 Notched Specimen Testing

Creep behavior of Alloy 617 has been extensively characterized to support the development of a draft Code Case to qualify Alloy 617 in Section III division 5 of the ASME Boiler and Pressure Vessel Code. This will allow use of Alloy 617 in construction of nuclear reactor components at elevated temperatures and longer periods of time (up to 950°C and 100,000 hours). Prior to actual use, additional concerns not considered in the ASME code need to be addressed. Code Cases are based largely on uniaxial testing of smooth gage specimens. In service conditions, components will generally be under multi axial loading. There is also the concern of the behavior at discontinuities, such as threaded components. To address the concerns of multi axial creep behavior and at geometric discontinuities, notched specimens have been designed to create conditions representative of the states that service components experience. Two general notch geometries have been used for these series of tests: U notch and V notch specimens. The notches produce a tri axial stress state, though not uniform across the specimen. Characterization of the creep behavior of the U notch specimens and the creep rupture behavior of the V notch specimens provides a good approximation of the behavior expected of actual components. Preliminary testing and analysis have been completed and are reported in this document. This includes results from V notch specimens tested at 900°C and 800°C. Failure occurred in the smooth gage section of the specimen rather than at the root of the notch, though some damage was present at the root of the notch, where initial stress was highest. This indicates notch strengthening behavior in this material at these temperatures.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Quarter 2 Research Performance Progress Report (RPPR) - DOE Solar Program

Creep-fatigue deformation is an important consideration for a thermal receiver of a gas phase (GP) Concentrating Solar Power (CSP) system due to the constant static stress or pressure, diurnal cycling, and elevated service temperatures required for efficient operation. An accurate description of the creep-fatigue behavior, not available for five of the six candidate materials, is important for assessment of preliminary designs. This project will provide a detailed analysis of the creep-fatigue behavior and damage accumulation of a candidate structural material for a CSP solar thermal receiver to address a critical knowledge barrier for receiver design in the GP pathway concept identified in the CSP Gen3 Demonstration Roadmap. This effort includes the development of rules for the design of solar receiver components against high temperature creep-fatigue and ratcheting failure modes. The ASME Code rules for high temperature nuclear components will form the basis of the method but adjustments will be made to reflect the generally shorter, diurnal operating cycles of thermal receivers and the relative consequences of failure, comparing nuclear to solar components. This is report covers the second quarter's work, which addressed outstanding questions on alloy selection for Quarter 1, and began laying the ground work for mechanical testing.

14 SOLAR ENERGY↗

DOE OSTI2017

Report on Resolution of Regulatory Issues for VHTR Materials: Notch Effects

A better understanding of the high temperature behavior of Inconel 617 is needed prior to use in upcoming high temperature nuclear power plants. Previous work has extensively characterized uniaxial creep behavior. The current work continues this effort and examines the effects of discontinuities and multi-axial stress states on creep of 617 at high temperatures (700-900 °C). In addition to macroscopic analysis of creep specimens, local deformation and damage is examined through use of EBSD analysis and quantitative metallography. The results are critical to linking complex geometries and stress states of actual components to the extensive uniaxial creep database.

36 MATERIALS SCIENCE↗

NASA NTRS2017

SiC Fibers and SiCf/SiC Ceramic Matrix Minicomposites Damage Behavior

Silicon Carbide based Ceramic Matrix Composites (CMCs) are attractive materials for use in high-temperature applications in the aerospace industry. Performance and durability of CMCs depend on the properties of its constituents such as fibers and matrix. Therefore, CMCs constituents limitations and damage mechanisms are discussed and characterized in representative simulated application conditions and dominant damage mechanisms are identified at elevated temperatures. In this work, the initiation and evolution of damage in Hi-Nicalon type S fiber-reinforced minicomposites with different interphases thicknesses from different manufacturers were investigated employing several nondestructive evaluation techniques such as acoustic emission, electrical resistance and microscopy. Moreover, the tensile creep behavior of single Hi-Nicalon Type S SiC fibers were tested and characterized and creep parameters were extracted. Fibers creep tests were performed in air or vacuum at 1200-1482 C under high stresses. Creep parameters was then used in understanding load sharing and lifing of ceramic matrix minicomposites. Future work plans will be reviewed.

SiC fibers↗

NASA NTRS2024

Effects of alloying elements on twinning in Ni-based superalloys

Micro-twinning is the major creep deformation mechanism in Ni-based superalloys at temperatures above 700 °C. Recent experiments suggest that superlattice stacking faults in y' phase may serve as the precursors to twin formation. Segregation of alloying elements to these precursors may have a significant effect on formation and extension of micro-twins. Using atomistic modeling we investigate and explain the effects of Nb and Cr alloying additions on these processes. The simulation shows that Nb increases the creep resistance which is mostly associated with impeding the reordering of the high energy double complex stacking fault. Cr, on the other hand, promotes twin growth, degrading the high temperature creep properties. These results can help to understand the effects of elemental composition of the alloy on creep resistance.

Ni-based superalloys↗

NASA NTRSDate not supplied

Effects of Alloying Elements on Twinning in Ni-Based Superalloys

Ni-based superalloys↗

DOE OSTI2011

NUMERICAL SIMULATION FOR MECHANICAL BEHAVIOR OF U10MO MONOLITHIC MINIPLATES FOR RESEARCH AND TEST REACTORS

This article presents assessment of the mechanical behavior of U-10wt% Mo (U10Mo) alloy based monolithic fuel plates subject to irradiation. Monolithic, plate-type fuel is a new fuel form being developed for research and test reactors to achieve higher uranium densities within the reactor core to allow the use of low-enriched uranium fuel in high-performance reactors. Identification of the stress/strain characteristics is important for understanding the in-reactor performance of these plate-type fuels. For this work, three distinct cases were considered: (1) fabrication induced residual stresses (2) thermal cycling of fabricated plates; and finally (3) transient mechanical behavior under actual operating conditions. Because the temperatures approach the melting temperature of the cladding during the fabrication and thermal cycling, high temperature material properties were incorporated to improve the accuracy. Once residual stress fields due to fabrication process were identified, solution was used as initial state for the subsequent simulations. For thermal cycling simulation, elasto-plastic material model with thermal creep was constructed and residual stresses caused by the fabrication process were included. For in-service simulation, coupled fluid-thermal-structural interaction was considered. First, temperature field on the plates was calculated and this field was used to compute the thermal stresses. For time dependent mechanical behavior, thermal creep of cladding, volumetric swelling and fission induced creep of the fuel foil were considered. The analysis showed that the stresses evolve very rapidly in the reactor. While swelling of the foil increases the stress of the foil, irradiation induced creep causes stress relaxation.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2016

Development of Surface Grain Relief on Self-Ion Irradiated Copper

The development of surface grain relief has been observed on self-ion irradiated pure polycrystalline copper. However, the mechanistic origin of this feature has yet to be determined. Two possible mechanisms, anisotropic creep relaxation of void swelling induced stresses and crystallographic orientation-dependent sputtering rate differences, are being investigated as the cause of this evolution. This work focuses on characterizing the surface development and investigating the mechanism of orientation-dependent sputtering. Based on the conditions under which these specimens were irradiated, preferential sputtering is not likely to be the cause of the observed grain relief. Surface grain relief can greatly influence the ability to non-destructively detect irradiation-induced effects in polycrystalline metals. Determining the origin of grain relief development is necessary before this surface feature can be used an indicator of irradiation-induced effects in pure copper and other alloys. The development of surface grain relief has been observed on self-ion irradiated pure polycrystalline copper irradiated to 100 dpa. This surface feature was first noted by measuring samples using transient grating spectroscopy and later confirmed using scanning electron microscopy. Calculations of single-crystal sputtering rates show that the difference in sputtering yields between a randomly-oriented solid and a low-index plane is not sufficient to account for the observed height difference. SEM images appear to show a maximum step-height difference of around 100 nm and differential sputtering can only account for differences on the order of 10 nm at most. This determination indicates that anisotropic creep relaxation may be the mechanistic origin of the observed surface features. If this is the case, which will be confirmed by future work, then TG spectroscopy may be an effective tool for the determination of the onset of certain radiation-damage evolution. For example, if the onset of creep relaxation is strongly correlated to a specific level of void swelling and if the surface features present as a result of creep relaxation can be observed using TG spectroscopy, then accurate determinations of particular levels of void swelling may be made. (authors)

36 MATERIALS SCIENCE↗

DOE OSTI2022

GCR: Development of Improved Alloy 800H Weldment

In Section III, Division 5 of the American Society of Mechanical Engineers Boiler and Pressure Vessel Code, Alloy 800H is qualified for elevated-temperature nuclear construction for temperatures up to 760°C (1400°F) and a maximum service life of 300,000 hours. There are two permissible filler metals for Alloy 800H weldments specified in Division 5: ENiCrFe-2 (Alloy A) and ERNiCr-3 (Alloy 82). Low creep-rupture strengths of these weldments at the upper limits of the qualified temperatures and service lives may restrict the design envelope for elevated-temperature nuclear construction with Alloy 800H. As a result, an alternative filler metal is desired to improve the creep-rupture strengths of Alloy 800H weldments for the qualified temperatures and service lives. This work investigates an overmatched filler metal. Specifically, a weldment with Alloy 800H base metal and Alloy 617 filler metal fabricated by semiautomated gas tungsten arc welding is investigated. A scoping creep-rupture test program was conducted of cross-weld specimens at temperatures ranging from 750 to 1000°C (1292 to 1832°F). Preliminary results on the creep-rupture strengths of the Alloy 800H weldment with an Alloy 617 filler metal do not show significant improvement compared to the filler metals currently qualified in Division 5 for Alloy 800H weldments. Consequently, work is in progress to investigate a matching filler metal, UTP A 2133 Mn.

36 MATERIALS SCIENCE↗