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Co-dependent microstructural evolution pathways in metastable d-ferrite in cast austenitic stainless steels during thermal aging
Cast austenitic stainless steels (CASS) are excellent alloys because they combine high corrosion resistance with high strength and toughness. However, they are susceptible to embrittlement upon long-term thermal aging at elevated temperatures. Thus, the microstructural evolution pathways during thermal aging need to be understood to predict and potentially prevent embrittlement. Atom probe tomography was used to identify and quantify the microstructural evolution pathways of the d-ferrite in different CASS alloys aged for up to 10,000 hours at temperatures between 290 °C and 400 °C. The four steels – CF8, CF8M, CF3, and CF3M – which vary by Mo and C concentration, each experienced spinodal decomposition of the d-ferrite, and precipitation of G-phase clusters and Cu clusters attached to the G-phase. There were large differences in the extent of these features due to their Mo and C concentration. Using radial distribution function analysis, the interactions of constituent elements was found to determine the evolution of these features, with Mo and C specifically influencing the movement of Cr, Ni, Si, Mn, and Cu atoms due to their relative miscibility with these elements. The results will help inform predictive models for the use of duplex stainless steels for extended operation at high temperatures.
Investigation of temperature dependence of fracture toughness in high-dose HT9 steel using small-specimen reuse technique
The temperature dependence of fracture toughness in HT9 steel irradiated to 3–145 dpa at 380–503 degrees*C was investigated using miniature three-point bend (TPB) fracture specimens. A miniature-specimen reuse technique has been established: the tested halves of subsize Charpy impact specimens with dimensions of 27 mm *3mm* 4 mm were reused for this fracture test campaign by cutting a notch with a diamond-saw in the middle of each half, and by fatigue-precracking to generate a sharp crack tip. It was confirmed that the fracture toughness of HT9 steel in the dose range depends more strongly on the irradiation temperature than the irradiation dose. At an irradiation temperature <430 *degreesC, the fracture toughness of irradiated HT9 increased with the test temperature, reached an upper shelf of 180—200 MPa*m^.5 at 350–450 degrees*C, and then decreased with the test temperature. At an irradiation temperature >430 degrees*C, the fracture toughness was nearly unchanged up to about 450 *degreesC and decreased slowly with test temperatures in a higher temperature range. Such a rather monotonic test temperature dependence after high-temperature irradiation is similar to that observed for an archive material generally showing a higher degree of toughness. A brittle fracture without stable crack growth occurred in only a few specimens with relatively lower irradiation and test temperatures. In this discussion, these TPB fracture toughness data are compared with previously published data from 12.7 mm diameter disc compact tension (DCT) specimens.
In Situ Measurement of Tritium Permeation Through Stainless Steel
The TMIST-2 irradiation experiment was conducted in the Advanced Test Reactor at Idaho National Laboratory to evaluate tritium permeation through Type 316 stainless steel (316 SS). The interior of a 316 SS seamless tube specimen was exposed to a 4He carrier gas mixed with a specified quantity of tritium (T2) to yield partial pressures of 0.1, 5, and 50 Pa at 292° and 330°C. In-situ tritium permeation measurements were made by passing a He-Ne sweep gas over the outer surface of the specimen to carry the permeated tritium to a bubbler column for liquid scintillation counting. An irradiation enhancement factor (IEF) was determined by comparing in-situ permeation data with a correlation for ex-reactor hydrogen permeation through austenitic stainless steel developed from literature data and reported by Le Claire. Nominal values for the IEF ranged between 3 and 5 for 316 SS. In-situ permeation data were also used to derive an in-reactor permeation correlation as a function of temperature and pressure. In addition, the triton recoil contribution to tritium permeation, which results from the transmutation of 3He to T, was also evaluated by introducing a 4He carrier gas mixed with 3He at a partial pressure of 1013 Pa at 330°C. Less than 3% of the tritium resulting from 3He transmutation contributed to tritium permeation.
Load partitioning between ferrite/martensite and dispersed nanoparticles of a 9Cr ferritic/martensitic (F/M) ODS steel at high temperatures
In this study, a high-energy synchrotron radiation X-ray technique was used to investigate the tensile deformation processes of a 9Cr-ODS ferritic/martensitic (F/M) steel at different temperatures. Two minor phases within the 9Cr-ODS F/M steel matrix were identified as Y2Ti2O7 and TiN by the high-energy X-ray diffraction, and confirmed by the analysis using energy dispersive X-ray spectroscopy (EDS) of scanning transmission electron microscope (STEM). The lattice strains of the matrix and particles were measured through the entire tensile deformation process. During the tensile tests, the lattice strains of the ferrite/martensite and the particles (TiN and Y2Ti2O7) showed a strong temperature dependence, decreasing with increasing temperature. Analysis of the internal stress at three temperatures showed that the load partitioning between the ferrite/martensite and the particles (TiN and Y2Ti2O7) was initiated during sample yielding and reached to a peak during sample necking. At three studied temperatures, the internal stress of minor phases (Y2Ti2O7 and TiN) was about 2 times that of F/M matrix at yielding position, while the internal stress of Y2Ti2O7 and TiN reached about 4.5-6 times and 3-3.5 times that of the F/M matrix at necking position, respectively. It indicates that the strengthening of the matrix is due to minor phases (Y2Ti2O7 and TiN), especially Y2Ti2O7 particles. Although the internal stresses of all phases decreased with increasing temperature from RT to 600 degrees C, the ratio of internal stresses of each phase at necking position stayed in a stable range (internal stresses of Y2Ti2O7 and TiN were about 4.5-6 times and 3-3.5 times of that of F/M matrix, respectively). The difference between internal stress of the F/M matrix and the applied stress at 600 degrees C is slightly lower than those at RI and 300 degrees C, indicating that the nanoparticles still have good strengthening effect at 600 degrees C. (C) 2015 Elsevier B.V. All rights reserved.
Radiation-induced swelling and radiation-induced segregation & precipitation in dual beam irradiated Ferritic/Martensitic HT9 steel
Highlights: • The depth-dependence of radiation-induced cavities was characterized in self-ion irradiated HT9 co-implanted with He. • The injected interstitial effect was revealed to suppress cavity swelling in the vicinity of the damage peak. • ChemiSTEM elemental maps revealed the segregation of Ni at cavity surfaces and its possible synergistic influence on swelling was discussed. - Abstract: Ferritic/Martensitic HT9 steel was irradiated at 432 °C to 16.6 displacements per atom (dpa) (at the depth of 600 nm) using a defocused beam of 5 MeV Fe{sup ++} ions, while co-implanted with 3.22 appm He at the same depth. The helium concentration profile was designed so to follow the damage curve with a 0.22 appm He/dpa ratio at the depth from 300 to 1000 nm in the material. The depth-dependence of the cavity size and number density were characterized by both transmission electron microscopy (TEM) and scanning transmission electron microscopy (STEM) imaging methods. A comparison between the two techniques was done showing good agreement. Cavity number density and the resulting swelling were found to be suppressed by the injected interstitial effect in the vicinity of the ion induced damage peak. The region between 300 and 750 nm depth which excludes the injected interstitial effect was thus proposed for improved cavity swelling analysis. The swelling ratio in this region was found to be ~(0.86–1.02) × 10{sup − 2}%/dpa. In addition, ChemiSTEM characterization revealed radiation-induced segregation occurring throughout the irradiated region and precipitation of G-phase particles. Segregation of Ni to cavity surfaces was also observed and its possible synergistic influence on swelling was discussed.
A Composite Modeling Analysis of the Deformation Behavior of Medium Manganese Steels
The deformation behavior of medium manganese steels was evaluated with uniaxial tensile testing and the results were correlated with predictions of a composite model shown previously to provide design insight into the development of multi-phase steels with third-generation advanced high strength steel (3GAHSS) properties. An equilibrium thermodynamic-based methodology to design microstructures containing systematic amounts of metastable austenite with controlled stability against transformation is presented. The analysis is based on Mn enrichment of austenite during intercritical annealing of medium Mn (7 and 10 wt pct.) low carbon (0.1 and 0.15 wt pct) steels. The steels were produced as laboratory heats that were hot and cold rolled prior to annealing. After annealing the microstructures consisted primarily of either a matrix of fine grained ferrite with austenite contents between 32.6 and 45.2 wt pct (7Mn, 0.1C steels) or a matrix of martensite with various amounts of austenite in the higher Mn steel. The different intercritical annealing conditions produced steels with wide variations in austenite contents and austenite compositions (Mn and C contents) resulting in steels with significant variations in austenite stability. Predictions based on the composite analysis with different assumed flow behaviors for the individual constituents and stability functions for the meta-stable austenite are presented and shown to accurately predict strength-ductility combinations over a range of austenite volume fractions for the 7Mn steel. Applicability of the composite analysis is extended to consider the deformation behavior of the 10Mn steel and evaluate other possible microstructural combinations leading to 3GAHSS properties.
Computational material design for Q&P steels with plastic instability theory
In this paper, the deformation limits of Quenching and Partitioning (Q&P) steels are examined with the plastic instability theory. For this purpose, the constituent phase properties of various Q&P steels were first experimentally obtained, and used to estimate the overall tensile stress-strain curves based on the simple rule of mixture (ROM) with the iso-strain and iso-stress assumptions. Plastic instability theory was then applied to the obtained overall stress-strain curves in order to estimate the deformation limits of the Q&P steels. A parametric study was also performed to examine the effects of various material parameters on the deformation limits of Q&P steels. Computational material design was subsequently carried out based on the information obtained from the parametric study. The results show that the plastic instability theory with iso-stress-based stress-strain curve may be used to provide the lower bound estimate of the uniform elongation (UE) for the various Q&P steels considered. The results also indicate that higher austenite stability/volume fractions, less strength difference between the primary phases, higher hardening exponents of the constituent phases are generally beneficial for the performance improvement of Q&P steels, and that various material parameters may be concurrently adjusted in a cohesive way in order to improve the performance of Q&P steel. The information from this study may be used to devise new heat treatment parameters and alloying elements to produce Q&P steels with the improved performance.
Microstructural characterization in dissimilar friction stir welding between 304 stainless steel and st37 steel
In the present study, 3 mm-thick plates of 304 stainless steel and st37 steel were welded together by friction stir welding at a welding speed of 50 mm/min and tool rotational speed of 400 and 800 rpm. X-ray diffraction test was carried out to study the phases which might be formed in the welds. Metallographic examinations, and tensile and microhardness tests were used to analyze the microstructure and mechanical properties of the joint. Four different zones were found in the weld area except the base metals. In the stir zone of the 304 stainless steel, a refined grain structure with some features of dynamic recrystallization was evidenced. A thermomechanically-affected zone was characterized on the 304 steel side with features of dynamic recovery. In the other side of the stir zone, the hot deformation of the st37 steel in the austenite region produced small austenite grains and these grains transformed to fine ferrite and pearlite and some products of displacive transformations such as Widmanstatten ferrite and martensite by cooling the material after friction stir welding. The heat-affected zone in the st37 steel side showed partially and fully refined microstructures like fusion welding processes. The recrystallization in the 304 steel and the transformations in the st37 steel enhanced the hardness of the weld area and therefore, improved the tensile properties of the joint. - Highlights: Black-Right-Pointing-Pointer FSW produced sound welds between st37 low carbon steel and 304 stainless steel. Black-Right-Pointing-Pointer The SZ of the st37 steel contained some products of allotropic transformation. Black-Right-Pointing-Pointer The material in the SZ of the 304 steel showed features of dynamic recrystallization. Black-Right-Pointing-Pointer The finer microstructure in the SZ increased the hardness and tensile strength.
Relationship between lath boundary structure and radiation induced segregation in a neutron irradiated 9 wt.% Cr model ferritic/martensitic steel
Ferritic/Martensitic (F/M) steels with high Cr content posses the high temperature strength and low swelling rates required for advanced nuclear reactor designs. Radiation induced segregation (RIS) occurs in F/M steels due to solute atoms preferentially coupling to point defect fluxes which migrate to defect sinks, such as grain boundaries (GBs). The RIS response of F/M steels and austenitic steels has been shown to be dependent on the local structure of GBs where low energy structures have suppressed RIS responses. This relationship between local GB structure and RIS has been demonstrated primarily in ion-irradiated specimens. A 9 wt.% Cr model alloy steel was irradiated to 3 dpa using neutrons at the Advanced Test Reactor (ATR) to determine the effect of a neutron radiation environment on the RIS response at different GB structures. This investigation found the relationship between GB structure and RIS is also active for F/M steels irradiated using neutrons. The data generated from the neutron irradiation is also compared to RIS data generated using proton irradiations on the same heat of model alloy.
Precipitation-site competition in duplex stainless steels: Cu clusters vs spinodal decomposition interfaces as nucleation sites during thermal aging
Competing microstructural evolution mechanisms can exist simultaneously when duplex stainless steels are operating for several decades in a high temperature service environment. Such competition between different microstructural evolution pathways can be difficult to ascertain using simple model alloy systems necessitating detailed structural and compositional analysis of phase transformation mechanisms in complex alloys Thus, in this study duplex stainless steels with complex but well understood chemistries were used to investigate the relative importance of different heterogeneous nucleation sites – specifically spinodal decomposition and Cu clustering – on precipitation of Ni-Si-Mn particles during long term thermal aging. Precipitation of Ni-Si-Mn particles in duplex stainless steels and ferritic steels during thermal aging and irradiation is known to have profound effect on mechanical properties. Using duplex stainless steels with custom modified compositions along with atom probe tomography characterization and first-passage kinetic Monte Carlo (FPKMC) simulations it is revealed that while the interface between Cr and Fe formed during spinodal decomposition can be a pathway for diffusion of Ni, Si, Mn, and Cu, it is not a site that encourages precipitation of Ni-Si-Mn rich particles. Instead, the presence of a higher concentration of Cu in these steels leads to formation of small Cu clusters with high energy interfaces that act as nucleation sites for Ni-Si-Mn particles because of its strong interaction particularly with Ni increasing the chemical driving force for precipitation. These results will help inform predictive models for the use of duplex stainless steels and other precipitation-hardened alloys for extended operation at high temperatures.
Reducing Mass of Steel Auto Bodies using Thin Advanced High Strength Steel with Carbon-Fiber Reinforced Epoxy
Diversitak, a company based in Detroit, MI, has developed a proprietary, low specific gravity, carbon fiber-reinforced epoxy (CFRE) under U.S. patent number 9,963,58832. Preliminary testing on this new material conducted in collaboration with ArcelorMittal Steel Company proved out the CFRE concept. A thin layer of this CFRE was applied to a stamped sheet of steel with residual stamping oils from a mill, in a time corresponding to automotive processing (e.g., ~15 seconds), and processed following automotive e-coat procedures (phosphating + 175–200°C heating), to complete the curing. No problems with adherence or performance were noted. While the CFRE does add weight to a thin gauge steel panel, it weighs much less than what is displaced by using thicker conventional mild steel gauges. The application of the coating showed a significant increased dent resistance, oil canning resistance, and part stiffness.This current two-year project was designed to mature this new technology to near manufacturing readiness to reduce the weight of a vehicle and lower the cost of weight reduction. The process involves the use of thinner gauge steels than are currently used. The collaborative development team included two industrial manufacturers: Diversitak and ArcelorMittal Steel Company; LightMAT; and two National Laboratories: Oak Ridge National Laboratory (ORNL) and Idaho National Laboratory (INL). The team developed a new manufacturing process to reduce the weight of a vehicle and lower the cost of weight reduction, as well as a better understanding of how to apply the coating so that it will perform to a high standard in-service. The team also performed an in-depth study to determine the long-term durability of the materials manufactured using this technology and well-known automotive industry standard tests.The overall process involved stiffening the thinner gauge steel by applying the CFRE on only one side. To accomplish this goal, the optimal reinforcement fiber length and fiber concentration was first determined. This was followed by measuring the coefficient of thermal expansion (CTE) in all three directions, so it could be fed into manufacturing models and methods for rapidly and inexpensively applying the coating. This was followed by panel level evaluations of the coating and steel combination, and then by full part demonstration of the technology on door panels. The final step was corrosion testing of the parts.ArcelorMittal characterized the advanced high strength steel (AHSS) (e.g., metallurgy-heat treatment for required AHSS properties as a function of the sheet thickness, state of internal stress) and quantified CFRE adhesion to the steel as a function of sheet preparation (e.g., rolling and stamping).ORNL optimized the fiber length, fiber concentration, and coating thickness for best vehicle function and performance at the least cost. Along with the suppliers, ORNL developed a durable CFRE application process (e.g., gun material, design, robotic dispensing process) and identified the adhesion stability of the CFRE during process holding. An approach to ensure that application/curing timing conforms to conventional assembly line speed and plant cycle times was determined. ORNL also determined the CTE of the material in all three directions and performed material scanning electron microscopy (SEM) analyses.INL characterized the corrosion properties of the steel panels coated with CFRE. The panels were investigated for corrosion resistance and stability as replacement materials used in automotive body panels to reduce mass. The coupons tested at INL were supplied by Diversitak after an optimized CFRE formulation was achieved in the already coated form for corrosion testing.
Micro-Abrasion Wear Resistance of Borided 316L Stainless Steel and AISI 1018 Steel
The 316L stainless steel has high corrosion resistance but low tribological performance. In different industrial sectors (biomedical, chemical, petrochemical, and nuclear engineering), improvement upon wear resistance of 316L stainless steel components using accessible and inexpensive methods is critical. The AISI 1018 steel is widely used in industry, but its tribological performance is not the best among steels. Therefore, in this study the behavior of the borided 316L stainless steel and 1018 steel is evaluated under micro-abrasion wear. The boriding was carried out at 1223 K over 6 h of exposure time, resulting in a biphase layer composed of FeB/Fe{sub 2}B phases. In order to evaluate Fe{sub 2}B phase with no influence from FeB phase, AISI 1018 steel samples were borided at 1273 K for over 20 min and then diffusion annealed at 1273 K over 2 h to obtain a Fe{sub 2}B mono-phase layer. Micro-abrasion wear resistance was evaluated by a commercial micro-abrasion testing rig using a mix of F-1200 SiC particles with deionized water as abrasive slurry. The obtained wear rates for FeB and Fe{sub 2}B phases and for the 316L stainless steel were compared. Wear resistance of 316L stainless steel increases after boriding. The wear mechanisms for both phases and for the stainless steel were identified. Also, transient conditions for rolling and grooving abrasion were determined for the FeB and Fe{sub 2}B phases.
A Comparative Study on Formability of the Third-Generation Automotive Medium-Mn Steel and 22MnB5 Steel
Third-generation advanced automotive medium-Mn steel, which can replace 22MnB5 steel, was newly developed to improve the lightweight and crashworthiness of automobile. Studies on the formability and simulation method of medium-Mn steel have just been initiated. In this study, finite element simulation models of square-cup deep drawing were established based on various material property experiments and validated by experiments. The effects of blank holder force (BHF), fillet radii of tools (die and punch) on the maximum drawing depth (MDD), thickness distribution of the formed products, and the microstructure before and after forming were investigated and compared with those on 22MnB5 steel. Results show that the MDD of the two steels decreased with increased BHF but increased with the fillet radius of punch; however, the fillet radius of die showed no significant effect on the MDD for both steels. Compared with hot-formed 22MnB5 steel, the martensitic transformation of the hot-formed medium-Mn steel is rarely influenced by the process parameters; thus, it holds the complete, fine-grained, and uniform martensitic microstructure. Moreover, the medium-Mn has better formability, lower initial blank temperature, and smaller impact of BHF and fillet radius of tools on the hot-formed product. Thus, a theoretical basis for the replacement of 22MnB5 steel by medium-Mn steel in hot forming process is provided.
Rotary Inertia Friction Welding of Dissimilar High-Strength 422 Martensitic Stainless Steel and 4140 Low Alloy Steel for Heavy-Duty Engine Piston Fabrication
AISI 422 martensitic stainless steel with superior high temperature performance (oxidation resistance and strength) is under evaluation for replacing current heavy-duty piston crown materials, AISI 4140 martensitic steel and micro alloyed steel (MAS) 38MnSiVS5, to fabricate a multimaterial piston. This multimaterial piston concept further improved power density and fuel economy by allowing heavyduty diesel engines to operate at higher temperatures and pressures. Joining AISI 422 steel piston crowns with AISI 4140 steel piston skirts is a key manufacturing step for this multimaterial piston. However, the significant differences in strength, elevated temperature flow stress, alloy chemistry, and temper resistance between these two martensitic steels cause some weldability issues (cracking) and metallurgical challenges (alloying element migration/segregation) when using conventional fusion-based welding processes. Rotary inertia friction welding (RIFW), a solid-state welding process, has been the preferred method to join 4140 crowns to 4140 skirts (and MAS crowns to MAS skirts) in high-volume production of current heavy-duty diesel engine pistons. It has been used to join these two materials with relatively comparable alloy chemistry to fabricate pistons with MAS skirts and 4140 crowns. Meanwhile, RIFW has also been a preferred method of dissimilar metal welding. However, RIFW of dissimilar high-strength martensitic steels has yet to be widely pursued. The interfacial microstructure complexities created by the thermomechanical process and highly nonequilibrium phase transformations during RIFW are a significant challenge for understanding and predicting their joining behavior and have not been reported in detail. Here, in this work, defect-free AISI 422 steel-AISI 4140 multimaterial pistons were successfully fabricated using the RIFW process. The interfacial microstructure and mechanical properties of dissimilar 422/4140 steel RIFW in the as-welded condition were experimentally studied in detail. The results provide critical baseline information for understanding RIFW mechanisms and guiding subsequent postweld heat treatment (PWHT) practice.
Evolution of Oxide–Sulfide Complex Inclusions and Its Correlation with Steel Cleanliness During Electroslag Rapid Remelting (ESRR) of Tool Steel
The evolution of CaO-Al{sub 2}O{sub 3}-MgO-(SiO{sub 2}) inclusions associated with CaS during electroslag rapid remelting (ESRR) of the tool steel with ultra low oxygen (8 ppm) under protective atmosphere was investigated. Thermodynamic calculation was performed to evaluate the oxygen level of liquid steel and the inclusion evolution during ESRR with the help of FactSage software (CON2 database). The results demonstrated that the reoxidation of liquid steel took place during industrial ESRR, resulting in the oxygen pickup of approximately double content. The oxygen level in the steel was determined by [Al]-[O] equilibrium during ESRR, whereas FeO in the slag transferred oxygen into the liquid steel, as indicated by the significant oxygen pickup. The inclusions in the steel electrode are oxide–sulfide type of CaO-Al{sub 2}O{sub 3}-MgO partially wrapped with CaS. The original oxide inclusions that had not been removed in ESRR process were transformed to liquid CaO-Al{sub 2}O{sub 3}-SiO{sub 2}-MgO inclusions through reacting with the dissolved oxygen supplied from the reoxidation of liquid steel and concerned elements in liquid steel during ESRR. These CaO-Al{sub 2}O{sub 3}-SiO{sub 2}-MgO inclusions were invariably associated with patch-type or shell-type CaS, which hold different formation mechanisms. The inclusions ranging from 2 to 4 µm take up a dominant proportion (a little more than 50 pct of the total inclusions) in the remelted ingots, and those larger than 8 µm account for about 3 pct. Melting rates of ESRR not only exerted a negligible effect on the steel cleanliness and the removal efficiency of oxide inclusions, but also on the inclusion size distribution.
Corrosion Susceptibility of Cr–Mo Steels and Ferritic Stainless Steels in Biomass-Derived Pyrolysis Oil Constituents
In this work, to better understand and evaluate the corrosion performance of candidate structural steels and ferritic stainless steels for production, transport, and storage of biomass pyrolysis oils, corrosion studies were conducted in selected organic constituents of bio-oils, including catechol, formic acid, and their mixtures as well as lactobionic acid, using electrochemical impedance spectroscopy. R 2 , the resistance against corrosion reaction, was obtained by fitting measured impedance spectra into an equivalent circuit. The values of R 2 were then used to assess corrosion resistance of the steels in each organic constituent and mixture. Type 410 and 430 stainless steels were resistant to corrosion in all tested organic constituents, while 2.25Cr-1Mo steel was not. 9Cr-1Mo steel was corrosion resistant in catechol but not in the other mixtures that contained organic acids. On the basis of the results of this work, it is suggested that the corrosion resistance against organic acids is attributed to formation of a Cr-rich passive film that requires stainless steels with critical Cr levels in excess of approximately 11 wt %. In catechol-only solution, lower levels of Cr intermediate between that of 2.25Cr-1Mo steel and 9Cr-1Mo steel appeared sufficient.
Assessment of Cold Spraying Mild-Steel Powder onto Mild-Steel Substrate for Development of Waste Tank Repair System - 20515
Infrastructure for nuclear waste storage and processing (e.g., waste tanks, transfer pipelines, evaporators) at the U.S. Department of Energy (DOE) Hanford Site has been in service well beyond its original design life. Past corrosion control methods at Hanford for waste tanks have not been fully successful, as evidenced by leaks forming in tank AY-102, the first double-shell tank (DST) constructed, and significant degradation detected in the primary tanks of AP-102 and AY-101. Failure of infrastructure components can pose a significant risk to the environment, worker safety, and project schedules. Therefore, remotely deployable methods for repairing and extending the service life of the existing tank waste infrastructure are needed. Cold spray has been identified as a potential technique for performing in situ repairs and material buildup for life extension of waste storage and processing infrastructure. Cold-spray repair methods and technology are well-established and are used extensively by industry and the military for making repairs using dissimilar materials. Pacific Northwest National Laboratory is evaluating the process of making repairs using mild-steel powder applied to a mild-steel substrate to minimize the galvanic corrosion potential. This paper presents the initial results for a feasibility ('go/no-go') assessment as to whether low-density deposits with sound metallurgic bonds, to build-back steel plate material, can be achieved using existing commercial cold-spray equipment. An assessment of steel-on-steel deposit is necessary to determine if cold spray is a viable candidate for DST carbon steel plate restoration/repair and thus DST service life extension. Powder properties and preparation requirements have been investigated and operating conditions and parameters for depositing a cold-spray buildup of mild steel on a mild-steel substrate have been determined. Soundness of metallurgic bonding as a function of the operating parameters exercised and results from applying cold spray to lay a deposit over simulated small-diameter flaws in 1/2-inch mild-steel plate are presented. Application of in situ cold-spray repair to the DOE complex has the potential to reduce cost and schedule impacts associated with component failures and the need to procure and construct replacement infrastructure. (authors)