Electric field-assisted embedding of fiber optic sensors in structural materials for structural health monitoring
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36 MATERIALS SCIENCE↗
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Results for “structural materials”
Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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Lattice Design and Advanced Modeling to Guide the Design of High-Performance Lightweight Structural Materials
Lightweight structural materials are required to increase the mobility of fission batteries. The materials must feature a robust combination of mechanical properties to demonstrate structural resilience. The primary objective of this project is to produce lightweight structural materials whose strength-to-weight ratios exceed those of the current widely used structural materials such as 316L stainless steels (316L SS). To achieve this, advanced modeling and simulation tools were employed to design lattice structures with different lattice parameters and different lattice types. A process was successfully developed for transforming lattice-structures models into Multiphysics Object Oriented Simulation Environment (MOOSE) inputs. Finite element modeling (FEM) was used to simulate the uniaxial tensile testing of the lattice-structured parts to investigate the stress distribution at a given displacement. The preliminary results showed that the lattice-structured sample displayed a lower Young’s modulus in comparison with the solid material and that the unit cell size of the lattice had a minimal effect. The novelty here is to apply up-front modeling to determine the best structure for the application before actually producing the sample. The approach of using modeling as a guiding tool for preliminary material design can significantly save time and cost for material development.
36 MATERIALS SCIENCE↗
Lattice Structured Lightweight Structural Materials
The development of lightweight structural materials is crucial for enhancing the performance and deployment feasibility of fission batteries. This study aims to produce lightweight structural materials whose strength-to-weight ratios exceed those of current widely used structural materials. To achieve this, advanced modeling and simulation tools were employed to design lattice structures with different lattice parameters and different lattice types. A process was successfully developed for transforming lattice-structured models into Multiphysics Object Oriented Simulation Environment (MOOSE) inputs. Finite element modeling (FEM) was used to simulate the uniaxial tensile testing of the lattice-structured parts to investigate the stress distribution at a given displacement. The modeling results showed that the lattice-structured sample displayed a lower Young’s modulus in comparison to the solid material; the increase in solid shell thickness and blend radius enhances the mechanical performance; and the effect of unit cell size on macro scale stress is minimal. Tensile testing was conducted on the solid and lattice-structured materials fabricated by laser powder bed fusion (LPBF) additive manufacturing. The experimental results agreed well with the model prediction. The approach of using modeling as a guiding tool for preliminary material design can significantly save time and cost for new material development.
lightweight material↗
Development of Lightweight Structural Materials with Improved Properties for Fission Batteries
Fission batteries require lightweight structural materials that demonstrate structural resilience when subjected to repeated shutdown, transportation, startup cycles, and certain external conditions, including rare events such as seismic vibrations and tsunamis. The objectives of this project are (1) to produce lightweight structural materials whose strength-to-weight ratios and fatigue resistance exceed those of current widely used structural materials such as 316 stainless steels (SS316), and (2) to enhance radiation tolerance of structural materials over a suitable service temperature range. To achieve these, (1) a lattice structure will be produced, (2) advanced modeling and simulation tools will be employed to design lattice structures (e.g., a gyroid structure) that reduce stress concentrations and thus increase fatigue resistance, and (3) one-dimensional (1-D) carbon nanotubes will be added to enhance radiation resistance. To validate our solution, high-temperature tensile and fatigue testing, in combination with microstructure characterization, will be conducted on wrought materials, additively manufactured solid materials, and the designed lightweight lattice structure material. Ion irradiation, microstructure characterization, and nanoindentation will be carried out to investigate the effect of 1-D carbon nanotubes on radiation tolerance. Successful completion of this project will deliver a material to serve as a substitute for current SS316 using the same chemistry but with lighter weight and improved mechanical properties. In addition, a material with carbon nanotubes can be designed for improved radiation tolerance over a suitable service temperature range. This project will establish new techniques in innovative materials/lattice design, advanced macroscale properties prediction, and the application of state-of-the-art processes.
36 MATERIALS SCIENCE↗
Materials Genomics Search for Possible Helium‐Absorbing Nano‐Phases in Fusion Structural Materials
Abstract Civilian fusion demands structural materials that can withstand the harsh environments imposed inside fusion plasma reactors. The structural materials often transmute under 14.1 MeV fast neutrons, producing helium (He), which embrittles the grain boundary (GB) network. Here, it is shown that neutron‐friendly and mechanically strong nano‐phases with atomic‐scale free volume can have low He‐embedding energy and >10 at.% He‐absorbing capacity, and can be especially advantageous for soaking up He on top of resisting radiation damage and creep, provided they have thermodynamic compatibility with the matrix phase, satisfactory equilibrium wetting angle, as well as a high enough melting point. The preliminary experimental demonstration proves that is a good ab initio predictor of He shielding potency in nano‐heterophase materials, and thus, is used as a key feature for computational screening. In this context, a list of viable compounds expected to be good He‐absorbing nano‐phases is presented, taking into account , the neutron absorption and activation cross‐sections, the elastic moduli, melting temperature, the thermodynamic compatibility, and the equilbrium wetting angle of the nano‐phases with the Fe matrix as an example.
36 MATERIALS SCIENCE↗
Structural Materials Characterization Test Rig Development
Structural Materials Characterization Test Rig Development Project Summary
46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
Fundamentals of Structural Materials for Nuclear Energy
Fundamentals of Structural Materials for Nuclear Energy
36 - MATERIALS SCIENCE↗
The U.S. Fusion Materials Community Roadmap: Near-term research priorities for the development of plasma-facing and structural materials for fusion power plants
In response to the needs of a rapidly growing private fusion industry, the U.S. Fusion Materials Coordinating Committee (FMCC) and the broader U.S. fusion materials research community undertook an extensive effort to create a comprehensive roadmap for fusion materials development. The result of this effort was the U.S. Fusion Materials Community Roadmap (US-FMCR), which describes the steps needed to advance the technical maturity of leading candidates for plasma-facing materials and structural materials for fusion power plants from laboratory-scale experiments to a point of sufficient technological readiness for industrial adoption and implementation. However, researchers face significant resource constraints as well as very aggressive pilot plant development timelines. Thus, the research strategies detailed in the US-FMCR require further assessment to downselect the specific tasks that must be prioritized within the next two to three years, in order to make the most efficient use of funding, human resources, and experimental facilities. This paper presents an overview of the US-FMCR and its development process. We also present the subset of research objectives that the FMCC identified as the most urgent research priorities for the U.S. fusion materials research community. The state-of-the-art of materials research is also highlighted for each class of materials considered in the US-FMCR. The recommendations presented here integrate an extensive evaluation of the current status of fusion materials research with a broad cross-section of opinion from the wider U.S. fusion community.
Ferry, Sara [Massachusetts Institute of Technology↗
Development and Validation of MALAMUTE model for Electric Field Assisted Sintering of Structural Materials
Fusion power plant designs feature extreme material performance requirements for structural material candidates. In addition to conventional alloys, more advanced composites and oxide dispersion strengthened (ODS) alloys are being explored, however, achieving the desired microstructures to maximize performance using traditional manufacturing methods can be challenging. The advanced manufacturing (AM) electric field-assisted sintering (EFAS) technique offers improved control over the final microstructure through higher heating and cooling rates and moderate pressures. Modeling and simulation tools show promise in elucidating the process-structure-property-performance (PSPP) correlation for AM-produced parts, including the EFAS process. An inherently multiscale process, the EFAS technique aligns well with the multiscale modeling capability of the open-source Multiphysics Object-Oriented Simulation Environment (MOOSE)[cite]. We present here an electro-thermo-mechanical approach to modeling the EFAS process using the MOOSE Application Library for Advanced Manufacturing UTilitiEs (MALAMUTE) code. Prediction of the field and gradient distributions across the EFAS tooling is required to accurately describe the conditions for the lower-scale microstructural evolution models. In this work we present the MALAMUTE model developed to predict the electrical potential, temperature, and mechanical stress distribution across the EFAS graphite tooling and part at the larger engineering-scale. Validation of the MALAMUTE engineering-scale model is completed using data from experimental densification and pre-densified runs of iron powder via EFAS at 1000oC. These runs were conducted using a Thermal Technology DCS-5 EFAS system. Data collected during the experiment runs include the direct current (DC) supplied to the graphite tooling, the temperature of the graphite tooling as measured with a pyrometer, and the force applied to the top of the graphite tooling stack, and the data were recorded every 10 seconds. Our validation approach used the current and force data from the EFAS run as boundary condition inputs to the MAMALUTE simulation; the temperature data were used to evaluate the MALAMUTE EFAS model prediction. Results of the MALAMUTE simulations are employed to connect the external pyrometer temperature measurement to the temperature profile across the part undergoing consolidation. We investigate the impact of material property variation and mesh deformation on the temperature profile as predicted by MALAMUTE. We conclude by highlighting projects where the MALAMUTE EFAS modeling and simulation capabilities will be used to assist experimental design.
36 - MATERIALS SCIENCE↗
COMPUTER-AIDED LATTICE DESIGN AND ADVANCED MODELING FOR THE DEVELOPMENT OF LIGHTWEIGHT STRUCTURAL MATERIALS
The notion of a “fission battery” conveys a vision focused on realizing very simple “plug-and-play” nuclear systems that can be integrated into a variety of applications requiring affordable, reliable energy in the form of electricity and/or heat and function without operations and maintenance staff. Fission batteries require lightweight structural materials to increase their mobility, and the lightweight materials must demonstrate structural resilience under various conditions. The objective of this work is to develop lattice structured lightweight structural material featuring a good combination of mechanical properties using advanced modeling and simulation together with an advanced additive manufacturing technique such as laser powder bed fusion. The preliminary results show that different lattice structures and types can be successfully meshed using nTopology software, and the lattice structure data can be successfully transformed to Multiphysics Object-Oriented Simulation (MOOSE) Environment input. Finite Element Analysis (FEA) displays that, at macro/engineering scale simulation, the weight saving design has an obvious effect on tensile behavior such as effective elastic modulus and yield stress. The novel approaches of this work are (1) development of lattice structures for improved mechanical properties using advanced simulation and modeling techniques; and (2) model predictions of the mechanical properties (e.g., strength and stress distribution) of macroscopic materials in order to preliminarily select a lattice structure for additive manufacturing.
36 MATERIALS SCIENCE↗
Development of Lightweight Structural Materials with Improved Properties for Fission Batteries
The notion of a “fission battery” conveys a vision focused on realizing very simple “plug-and-play” nuclear systems that can be integrated into a variety of applications requiring affordable, reliable energy in the form of electricity and/or heat and function without operations and maintenance staff. Fission batteries require lightweight structural materials to increase their mobility, and the lightweight materials must demonstrate structural resilience under various conditions. The objective of this work is to develop lattice structured lightweight structural material featuring a good combination of mechanical properties using advanced modeling and simulation together with an advanced additive manufacturing technique such as laser powder bed fusion. The preliminary results show that different lattice structures and types can be successfully meshed using nTopology software, and the lattice structure data can be successfully transformed to Multiphysics Object-Oriented Simulation (MOOSE) Environment input. Finite Element Analysis (FEA) displays that, at macro/engineering scale simulation, the weight saving design has an obvious effect on tensile behavior such as effective elastic modulus and yield stress. The novel approaches of this work are (1) development of lattice structures for improved mechanical properties using advanced simulation and modeling techniques; and (2) model predictions of the mechanical properties (e.g., strength and stress distribution) of macroscopic materials in order to preliminarily select a lattice structure for additive manufacturing.
36 MATERIALS SCIENCE↗
Development of Lightweight Structural Materials with Improved Properties for Fission Batteries
The notion of a “fission battery” conveys a vision focused on realizing very simple “plug-and-play” nuclear systems that can be integrated into a variety of applications requiring affordable, reliable energy in the form of electricity and/or heat and function without operations and maintenance staff. Fission batteries require lightweight structural materials to increase their mobility, and the lightweight materials must demonstrate structural resilience under various conditions. The objective of this work is to develop lightweight structural material featuring a good combination of mechanical properties using advanced modeling and simulation together with an advanced additive manufacturing technique such as laser powder bed fusion. The preliminary results show that different lattice structures and types can be successfully meshed using nTopology software, and the lattice structure data can be successfully transformed to Multiphysics Object-Oriented Simulation Environment (MOOSE) input. Finite Element Analysis (FEA) displays that, at macro/engineering scale simulation, the weight saving design has an obvious effect on tensile behavior such as effective elastic modulus and yield stress. The novel approaches of this work are (1) development of optimized lattice structures for improved mechanical properties using advanced simulation and modeling techniques; and (2) model predictions of the mechanical properties (e.g., strength and stress distribution) of macroscopic materials in order to preliminarily select a lattice structure for additive manufacturing.
36 MATERIALS SCIENCE↗
The Combinatorial Approach to Testing and Characterization of Irradiated Fuels and Reactor Structural Materials
Testing and characterization of irradiated fuels and reactor structural materials
36 - MATERIALS SCIENCE↗
Density Functional Theory Analysis of Candidate Tritium Permeation Barriers for Vanadium Alloys as a Fusion Structural Material
Vanadium alloys are being considered as a candidate structural material for the breeder blanket component of future fusion reactors due to their good thermal conductivity, low activation, and chemical compatibility with FLiBe. However, vanadium has a high hydrogen solubility, resulting in hydrogen diffusion and trapping in the vanadium structural alloy and lower than expected tritium breeding ratios. To mitigate the permeation of hydrogen into the structural alloy, a tritium permeation barrier will be coated onto the vanadium alloy. Multiple materials have been proposed as candidate tritium permeation barriers, but the extent to which each of these materials impacts hydrogen diffusion and trapping is still unknown. In this project, we perform atomic-scale calculations to narrow down the list of potential tritium permeation barrier candidates and to understand the mechanisms through which hydrogen diffusion is affected in these materials.
36 MATERIALS SCIENCE↗
The Combinatorial Approach to Testing and Characterization of Irradiated Fuels and Reactor Structural Materials
Testing and characterization of irradiated fuels and reactor structural materials
36 - MATERIALS SCIENCE↗
Effect of metal fluorides on the corrosion of structural materials in molten LiF-NaF-KF
The corrosion of structural materials in molten fluoride salts is predominantly caused by the presence of impurities in the salt. Here, this study focuses on understanding the corrosion behavior of selected alloys in molten FLiNaK salt with addition of similar quantities of metal fluoride impurities such as CrF 2 , CrF 3 , FeF 2 , FeF 3 , and NiF 2 . The results show that the presence of selected metal fluoride impurities increases the extent of corrosion of the selected alloys in molten FLiNaK salt, with the exact effect depending on the thermodynamic stability of the fluoride impurity added as well as the composition of the structural alloy studied.
36 MATERIALS SCIENCE↗
Integration Plan for NEAMS Structural Materials and Chemistry MSR Modeling
As part of its broad objective to support advanced reactor development, the US Department of Energy’s Nuclear Energy Advanced Modeling and Simulation (NEAMS) program has a strong interest in developing simulation capabilities to address chemistry and corrosion issues for molten salt reactors (MSRs). To that end, the Structural Materials & Chemistry (SMC) technical area within the NEAMS program is developing a set of codes and databases to describe the behavior of molten salts and their interactions with structural materials. This document reviews the current activities with respect to MSR-relevant codes and is an effort to improve their integration in simulating MSR systems. Interoperability between the codes being developed is critical for the success of the NEAMS-developed MSR simulation capability. This is greatly facilitated by having codes based on the MOOSE framework when possible, and by developing interfaces to MOOSE-based tools for those tools that are not based on that framework.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
Instrumentation for the In-Core Real-Time Mechanical Testing of Structural Materials (INCREASE) Project
Idaho National Laboratory (INL), in collaboration with the Electric Power Research Institute (EPRI), the Nuclear Regulatory Commission (NRC), the French Atomic and Alternative Energies Commission (CEA), the Joint Research Center (JRC), the Nuclear Research and Consultancy Group (NRG), and the Research Center Rez (CVR), started a Joint Experimental Program (JEEP) project that operates within the Nuclear Energy Agency’s Framework for Irradiation Experiments (FIDES II) program in order to develop capabilities for the in-core real-time mechanical testing of structural materials. This effort will focus on designing a shared capsule capable of housing a variety of in-core mechanical testing instrumentation allowing enhanced experiments for the material science community. The outcome of the project would be high-priority, stress relaxation data for stainless-steel-based materials provided by EPRI and CEA. Stress relaxation is a major phenomenon that contributes to material degradation in nuclear reactor components. Currently, nuclear material stress relaxation is assessed both before and after irradiation, using complex and costly post-irradiation examination (PIE) activities. In-situ data would support the development of precision modeling and simulation of this degradation phenomena and would provide validation and benchmarking for existing models using the PIE data. As part of the U.S. Department of Energy Advanced Sensor and Instrumentation (ASI) program, INL has fabricated and tested out-of-core mechanical test instrumentation. This instrumentation was designed for easy adaptation to the irradiation capsule proposed under this JEEP, and can be deployed to measure real-time stress relaxation under pressurized-water reactor (PWR) conditions. This initial effort will partially serve to replace the testing capabilities lost because of shutting down the Halden Boiling Water Reactor (HBWR). The project would provide these capabilities to the international community via a shared capsule design that is easily adaptable to additional material test reactors. The design features will incorporate expansion to PWR and non-light-water reactor (LWR) environments that will be developed in future work. The capsule and instrumentation will be demonstrated in the Massachusetts Institute of Technology Reactor (MITR) for phase I and the Petten High Flux Reactor (HFR) for phase II irradiations to deliver real-time stress relaxation data on high priority stainless steel structural materials.
36 MATERIALS SCIENCE↗