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Erosion characteristics of tungsten-alternative plasma-facing materials (PFMs) were tested under high heat flux conditions in the electrothermal plasma source facility at Oak Ridge National Laborat...

Tungsten is the material of choice as the plasma-facing material in future plasma-burning fusion reactors. During operation, plasma-facing materials will be simultaneously exposed to 14-MeV...

Thirteen austenitic stainless steels, nickel-base alloys, and ferritic alloys were irradiated using 2 MeV protons at 360 °C to a damage level of 2.5 displacements per atom (dpa). Comprehensive microstructural characterization was performed for irradiation-induced features, including dislocation loops, voids, precipitates, and radiation induced segregation (RIS). Dislocation loops formed in all alloys except 14YWT, while voids were observed in alloys 316 L, 310, C22, and 14YWT. Irradiation-induced formation of γ′ precipitates was observed in alloys 316 L, 310, 800, and 690; the irradiation-enhanced, long-range ordered Ni2Cr phase (Pt2Mo-type) was observed in alloys 690, C22, 625, 625Plus, 625DA, and 725; and G-phase was observed in alloy T92. No irradiation-induced precipitates were observed in alloys X750, 718 or 14YWT. Precipitation of the γ′ phase can be understood through segregation and clustering of Si, Al, and Ti. Overall, austenitic stainless steels are generally susceptible to irradiation damage in the form of loops, voids, precipitates, and RIS. Ni-base alloys have this same type of dislocation loops and RIS behaviors but are more resistant to void swelling. Ferritic alloys showed better resistance to loop formation, void swelling and irradiation-induced precipitation. From the degree of irradiation-induced microstructural change, alloy T92 was identified as the most radiation resistant among these alloys.

Nano-infiltration and transient eutectic phase (NITE) sintering was developed for fabrication of nuclear grade SiC composites. We produced monolithic SiC ceramics using NITE sintering, as candidates for accident-tolerant fuels in light-water reactors (LWRs). In this work, we exposed three different NITE chemistries (yttria-alumina [YA], ceria-zirconia-alumina [CZA], and yttria-zirconia-alumina [YZA]) to autoclave conditions simulating LWR coolant loops. The YZA was most corrosion resistant, followed by CZA, with YA being worst. High-resolution elemental analysis using scanning transmission electron microscopy (STEM) X-ray mapping combined with multivariate statistical analysis (MVSA) datamining helped explain the differences in corrosion. YA-NITE lost all Al from the corroded region and the ytttria reformed into blocky precipitates. The CZA material lost all Al from the corroded area, and the YZA − which suffered the least corrosion −retained some Al in the corroded region. The results indicate that the YZA-NITE SiC is most resistant to hydrothermal corrosion in the LWR environment.

In a magnetic fusion energy (MFE) device, the plasma-facing materials (PFMs) will be subjected to tremendous fluxes of ions, heat, and neutrons. The response of PFMs to the fusion environment is still not well defined. Tungsten metal is the present candidate of choice for PFM applications such as the divertor in ITER. However, tungsten's microstructure will evolve in service, possibly to include recrystallization. How tungsten's response to plasma exposure evolves with changes in microstructure is presently unknown. In this work, we have exposed hot-worked and recrystallized tungsten to an 80 eV helium ion beam at a temperature of 900 °C to fluences of 2 × 1023 or 20 × 1023 He/m2. This resulted in a faceted surface structure at the lower fluence or short but well-developed nanofuzz structure at the higher fluence. There was little difference in the hot-rolled or recrystallized material's near-surface (≤50 nm) bubbles at either fluence. At higher fluence and deeper depth, the bubble populations of the hot-rolled and recrystallized were different, the recrystallized being larger and deeper. This may explain previous high-fluence results showing pronounced differences in recrystallized material. The deeper penetration in recrystallized material also implies that grain boundaries are traps, rather than high-diffusivity paths.

Upsetting tests on two newly developed Mn and Cr-containing Al-Mg-Si-Cu alloys with various Mn contents were carried out at a speed of 15 mm/s under upsetting temperature of 450 °C after casting and subsequent homogenization heat treatment using a 300-Tone hydraulic press. STEM experiments revealed that Mn and Cr-containing α-Al (MnCrFe)Si dispersoids formed during homogenization showed a strong pinning effect on dislocations and grain boundaries, which could effectively inhibit recovery and recrystallization during hot deformation in the two alloys. Recrystallization fractions after solution heat treatment following hot deformation were measured by EBSD technique. It was found that the recrystallization fractions of the two alloys were less than 30%, giving rise to lower recrystallization fraction in the alloy with higher amount of Mn, which had higher number density of dispersoids. This implied that the finely distributed α-dispersoids were rather stable against coarsening and they stabilized the microstructure by inhibiting dislocation recovery and recrystallization during elevated temperature exposure. Increasing the content of Mn could increase the number density as well as the aspect ratio of the dispersoids, and more significantly, the effect of retardation on recrystallization were further enhanced.

Surface morphologies of tungsten surfaces, both polycrystalline and single-crystal [1 1 0], were investigated using SEM and FIB/SEM techniques after implantations at elevated surfaces temperatures (1200–1300 K) using well-characterized, mono-energetic He ion beams with a wide range of ion energies (218 eV–250 keV). Nanofuzz was observed on polycrystalline tungsten (PCW) following implantation of 100-keV He ions at a flux threshold of 0.9 × 1016 cm−2 s−1, but not following 200-keV implantations with similar fluxes. No nanofuzz formation was observed on single-crystal [1 1 0] tungsten (SCW), despite fluxes exceeding those demonstrated previously to produce nanofuzz on polycrystalline tungsten. Pre-damaging the single-crystal tungsten with implanted C impurity interstitials did not significantly affect the surface morphologies resulting from the high-flux He ion implantations. The main factor leading to the different observed surface structures for the pristine and C-implanted single-crystal W samples appeared to be the peak He ion flux characterizing the different exposures. It was speculated that nanofuzz formation was not observed for any SCW target exposures because of increased incubation fluences required for such targets.

Ultrasonic additive manufacturing (UAM) is a solid-state process, which uses ultrasonic vibrations at 20 kHz along with mechanized tape layering and intermittent milling operation, to build fully functional three-dimensional parts. In the literature, UAM builds made with low power (1.5 kW) exhibited poor tensile properties when loaded along the Z-direction, i.e., normal to the interfaces. This reduction in properties is often attributed to the lack of bonding at the interfaces. The generality of this conclusion is evaluated further in 6061 aluminum alloy builds made with very high power UAM (9 kW). Tensile deformation behavior along X and Z directions were evaluated with small-scale in-situ mechanical testing equipped with high-resolution digital image correlation, as well as, multi-scale characterization of builds. Interestingly, even with complete metallurgical bonding across the interfaces without any discernable voids, poor Z-direction properties were observed. This reduction is correlated to coalescence of pre-existing shear bands at interfaces into micro voids, leading to strain localization and spontaneous failure on tensile loading.

Nanostructured ferritic alloys (NFAs) are new generation materials for use in high temperature energy systems, such as nuclear fission or fusion reactors. However, joining these materials is a concern, as their unique microstructure is destroyed by traditional liquid-state welding methods. The microstructural evolution of a friction stir welded 14YWT NFA was investigated by atom probe tomography, before and after a post-weld heat treatment (PWHT) at 1123K. The particle size, number density, elemental composition, and morphology of the titanium-yttrium-oxygen-enriched nanoclusters (NCs) in the stir and thermally-affected zones were studied and compared with the base metal. No statistical difference in the size of the NCs was observed in any of these conditions. After the PWHT, increases in the number density and the oxygen enrichment in the NCs were observed. Therefore, these new results provide additional supporting evidence that friction stir welding appears to be a viable joining technique for NFAs, as the microstructural parameters of the NCs are not strongly affected, in contrast to traditional welding techniques.

Equiatomic FeNiCoCrMn alloy has been reported to exhibit promising strength and ductility at cryogenic temperature and deformation mediated by nano-twining appeared to be one of the main reasons. We use the FeNiCoCrMn alloy as a base alloy to seek further improvement of its mechanical properties by alloying additional elements, i.e., interstitial carbon. Moreover, the effects of carbon on microstructures, mechanical properties and twinning activities were investigated in two different temperatures (77 and 293 K). With addition of 0.5 at% C, the high entropy alloy still remains entirely single phase face-centered cubic (FCC) crystal structure. We found that these materials can be cold rolled and recrystallized to produce a microstructure with equiaxed grains. Both strain hardening rate and strength are enhanced while high uniform elongations to fracture (~70% at 77 K and ~40% at 293 K) are still maintained. The increased strain hardening and strength could be caused by the promptness of deformation twinning in C-containing high entropy alloys.

Nanostructured ferritic alloys (NFAs) have outstanding high temperature creep properties and extreme tolerance to radiation damage. To achieve these properties, NFAs are fabricated by mechanical alloying of metallic and yttria powders. Atom probe tomography has demonstrated that milling times of at least 40 h are required to produce a uniform distribution of solutes in the flakes. After milling and hot extrusion, the microstructure consists of -Fe, high number densities of Ti-Y-O-vacancy-enriched nanoclusters, and coarse Y2Ti2O7 and Ti(O,C,N) precipitates on the grain boundaries. In contrast, the as-cast condition consists of -Fe with 50-100 m irregularly-shaped Y2Ti2O7 pyrochlore precipitates with smaller embedded precipitates with the Al5Y3O12 (yttrium-aluminum garnet) crystal structure indicating that this traditional processing route is not a viable approach to achieve the desired microstructure. The nano-hardnesses were also substantially different, i.e., 4 and 8 GPa for the as-cast and as-extruded conditions, respectively. These differences can be explained by the differences in the microstructure and the effects of the high vacancy content introduced by mechanical alloying, and the strong binding energy of vacancies with O, Ti, and Y atoms retarding diffusion.

The microstructure and phase composition of an AlCoCrFeNi high-entropy alloy (HEA) were studied in as-cast (AlCoCrFeNi-AC, AC represents as-cast) and homogenized (AlCoCrFeNi-HP, HP signifies hot isostatic pressed and homogenized) conditions. The AlCoCrFeNi-AC ally has a dendritric structure in the consisting primarily of a nano-lamellar mixture of A2 (disordered body-centered-cubic (BCC)) and B2 (ordered BCC) phases, formed by an eutectic reaction. The homogenization heat treatment, consisting of hot isostatic pressed for 1 h at 1100 °C, 207 MPa and annealing at 1150 °C for 50 h, resulted in an increase in the volume fraction of the A1 phase and formation of a Sigma (σ) phase. Tensile properties in as-cast and homogenized conditions are reported at 700 °C. The ultimate tensile strength was virtually unaffected by heat treatment, and was 396±4 MPa at 700 °C. However, homogenization produced a noticeable increase in ductility. The AlCoCrFeNi-AC alloy showed a tensile elongation of only 1.0%, while after the heat-treatment, the elongation of AlCoCrFeNi-HP was 11.7%. Thermodynamic modeling of non-equilibrium and equilibrium phase diagrams for the AlCoCrFeNi HEA gave good agreement with the experimental observations of the phase contents in the AlCoCrFeNi-AC and AlCoCrFeNi-HP. The reasons for the improvement of ductility after the heat treatment and the crack initiation subjected to tensile loading were discussed.

Diffusion plays a major role in the stability of microstructures to extreme conditions of high temperature and high doses of irradiation. In nanostructured ferritic alloys, first principle calculations indicate that the binding energy of vacancies is reduced by the presence of oxygen, titanium and yttrium atoms. Therefore, the number of free vacancies available for diffusion can be greatly reduced. The mechanical properties of these alloys, compared to traditional wrought alloys of similar composition and grain structure, is distinctly different, and the ultrafine grained alloy is distinguished by a high number density of Ti–Y–O-enriched nanoclusters and solute clusters, which drives the mechanical response. When a displacement cascade interacts with a nanocluster, the solute atoms are locally dispersed into the matrix by ballistic collisions, but immediately a new nanocluster reforms due to the local supersaturation of solutes and vacancies until the excess vacancies are consumed. The result of these processes is a structural material for advanced energy systems with a microstructure that is self-healing and tolerant to high doses of radiation and high temperatures.

This paper provides an overview of advanced scanning transmission electron microscopy (STEM) techniques used for characterization of irradiated BCC Fe-based alloys. Advanced STEM methods provide the high-resolution imaging and chemical analysis necessary to understand the irradiation response of BCC Fe-based alloys. The use of STEM with energy dispersive x-ray spectroscopy (EDX) for measurement of radiation-induced segregation (RIS) is described, with an illustrated example of RIS in proton- and self-ion irradiated T91. Aberration-corrected STEM-EDX for nanocluster/nanoparticle imaging and chemical analysis is also discussed, and examples are provided from ion-irradiated oxide dispersion strengthened (ODS) alloys. Finally, STEM techniques for void, cavity, and dislocation loop imaging are described, with examples from various BCC Fe-based alloys.

The microstructural changes of a tempered F82H ferritic–martensitic steel following He implantation at 60 and 500 °C have been examined by transmission electron microscopy (TEM) and atom probe tomography (APT). After irradiation at 500 °C, numerous He bubbles were formed throughout the matrix, whereas after irradiation at 60 °C, no bubbles were seen to form in the matrix. In both irradiations, He bubbles were observed to have formed within large carbide precipitates, determined by APT compositional analysis to be M23C6. The observed preferential He bubble formation in carbides during low temperature He irradiation occurs as a result of the diffusing He being trapped in the carbide due to the strong He–C bond. As the He concentration increases in the carbide due to trapping, He bubbles are formed.

An effort is underway at the Spallation Neutron Source (SNS) to redesign the 1st Generation high-nickel alloy proton beam window (PBW) to a 2nd Generation design that utilizes aluminum for the window material. One of the key challenges to implementation of an aluminum PBW at the SNS was selection of an appropriate joining method to bond an aluminum window to the stainless steel shielding structure of the PBW assembly. An explosively formed bond was selected as the most promising joining method for the aluminum PBW design and a testing campaign was conducted to evaluate the strength and efficacy of explosively formed bonds that were produced using two different interlayer materials: niobium and titanium. The characterization methods reported here include tensile testing, thermal-shock leak testing, optical microscopy, and advanced scanning electron microscopy. All tensile specimens examined failed in an aluminum interlayer and measured tensile strengths were all slightly greater than the native properties of the aluminum interlayer, while elongation values were all slightly lower. A leak developed in the test vessel with an niobium interlayer after repeated thermal-shock cycles, which was attributed to an extensive crack network that formed in an interfacial layer of a niobium-rich constituent phase located on the bond interfaces of the niobium interlayer; the test vessel with a titanium interlayer did not develop a leak under the conditions tested. Due to the experience gained from these characterizations, an explosively formed bond with a titanium interlayer was selected for the aluminum PBW design at the SNS.

A latest-generation aberration-corrected scanning/transmission electron microscope (STEM) is used to study heavy-ion-irradiated nanostructured ferritic alloys (NFAs). Results are presented for STEM X-ray mapping of NFA 14YWT irradiated with 10 MeV Pt to 16 or 160 dpa at −100 °C and 750 °C, as well as pre-irradiation reference material. Irradiation at −100 °C results in ballistic destruction of the beneficial microstructural features present in the pre-irradiated reference material, such as Ti–Y–O nanoclusters (NCs) and grain boundary (GB) segregation. Irradiation at 750 °C retains these beneficial features, but indicates some coarsening of the NCs, diffusion of Al to the NCs, and a reduction of the Cr–W GB segregation (or solute excess) content. Ion irradiation combined with the latest-generation STEM hardware allows for rapid screening of fusion candidate materials and improved understanding of irradiation-induced microstructural changes in NFAs.

Twinning and martensitic transformation have been investigated in nickel-enriched AISI 304 stainless steel subjected to tensile and indentation deformation. Using electron backscatter diffraction (EBSD), the morphology of α- and e-martensite and the effect of grain orientation to load axis on phase and structure transformations were analyzed in detail. It was found that the twinning occurred less frequently under indentation than under tension; also, twinning was not observed in [001] and [101] grains. In tensile tests, the martensite particles preferably formed at the deformation twins, intersections between twins, or at the twin-grain boundary intersections. Conversely, martensite formation in the indentation tests was not closely associated with twinning; instead, the majority of martensite was concentrated in the dense colonies near grain boundaries. Martensitic transformation seemed to be obstructed in the [001] grains in both tensile and indentation test cases. Under a tensile stress of 800 MPa, both α- and e-martensites were found in the microstructure, but at 1100 MPa only α-martensite presented in the specimen. Under indentation, α- and e-martensite were observed in the material regardless of the stress level.

Understanding the reliability of eutectic Sn-3.5Ag lead-free solders in high-temperature packaging applications is of significant interest in power electronics for the next-generation electric grid. Large-area (2.5 mm × 2.5 mm) Sn-3.5Ag solder joints between silicon dies and direct bonded copper substrates were thermally cycled between 5°C and 200°C. Sn crystal orientation and microstructure evolution during thermal cycling were characterized by electron backscatter diffraction in the scanning electron microscope. Comparisons were made between the observed initial texture and microstructure and its evolution during thermal cycling. Gradual lattice rotation and grain boundary misorientation evolution observed due to thermal cycling suggested a continuous recrystallization mechanism. Recrystallization behavior was correlated with dislocation slip activities.

Nanostructured ferritic alloy is a subcategory of oxide dispersion strengthened steels intended for advanced reactor applications. The complex ultrafine grained microstructure of an advanced nanostructured ferritic alloy, as determined by electron microscopy and atom probe tomography, is summarised. Three distinct populations of precipitates were observed: 20–50 nm Ti(N,O,C), 5–10 nm diameter Y2Ti2O7/Y2TiO5 and 1–4 nm diameter Ti,Y,O enriched nanoclusters. The first two populations were predominantly located along grain boundaries together with Cr, W and C segregation. A dense population of nanoclusters was observed both in the grain interior as well as on the grain boundaries. These nanoclusters are highly tolerant to high dose irradiation at elevated temperatures.

The viability of advanced oxidation-resistant Fe-base alloys to protect zirconium from rapid oxidation in high-temperature steam environments has been examined. Specimens were produced such that outer layers of FeCrAl ferritic alloy and Type 310 austenitic stainless steel were incorporated on the surface of zirconium metal slugs. The specimens were exposed to high-temperature 0.34 MPa steam at 1200 and 1300 °C. The primary degradation mechanism for the protective layer was interdiffusion with the zirconium, as opposed to high-temperature oxidation in steam. The FeCrAl layer experienced less degradation and protected the zirconium at 1300 °C for 8 h. Constituents of the Fe-base alloys rapidly diffused into the zirconium and resulted in the formation of various intermetallic layers at the interface and precipitates inside the bulk zirconium. The nature of this interaction for FeCrAl and 310SS has been characterized by use of microscopic techniques as well as computational thermodynamics. Finally, a reactor physics discussion on the applicability of these protective layers in light-water-reactor nuclear fuel structures is offered.

Ferritic/Martensitic (F/M) steels containing 9 wt.% Cr are candidates for structural and cladding components in the next generation of advanced nuclear fission and fusion reactors. Although it is known these alloys exhibit radiation-induced segregation (RIS) at grain boundaries (GBs) while in-service, little is known about the mechanism behind RIS in F/M steels. The classical understanding of RIS in F/M steels presents a mechanism where point defects migrate to GBs acting as perfect sinks. However, variation in grain boundary structure may influence the sink efficiency and these migration processes. A proton irradiated 9 wt.% Cr model alloy steel was investigated using STEM/EDS spectrum imaging and GB misorientation analysis to determine the role of GB structure on RIS at different GBs. An ab initio based rate theory model was developed and compared to the experimental findings. This investigation found Cr preferentially segregates to specific GB structures. The preferential segregation to specific GB structures suggests GB structure plays a key role in the mechanism behind radiation-induced segregation, showing that not all grain boundaries in F/M steels act as perfect sinks. The study also found how irradiation dose and temperature impact the radiation-induced segregation response in F/M steels.

A 14YWT nanostructured ferritic alloy (NFA) was implanted with He + ions to fluences of 6.75 × 1021 He m-2 at 400 °C in order to simulate the effects of high He concentrations produced in advanced ...

Molybdenum is known to affect microalloy precipitate evolution during processing in ferrite and austenite, but a unified explanation of the role of Mo in precipitate evolution is still lacking. Experiments and thermodynamic calculations indicate that Mo is incorporated into (Nb,Mo)(C,N) precipitates both in the hot-rolled condition and after reheating to 900 °C. Molybdenum enrichment is reduced after reheating and soaking at 1100 °C. No measurable segregation of Mo to the carbonitride–matrix interface was observed in any condition.

Zircaloy-702 (Zr-702 or UNS R60702) cylindrical tubes are commonly used for applications requiring mechanical stability in extreme environments. Owing to its crystal structure and processing techniques, significant texture and anisotropic mechanical properties are possible. In the current study, combined axial-torsional testing is employed to probe macroscopic stress–strain behavior in three dimensions, and corresponding yield surface in octahedral plane is obtained. Zr-702 tube samples are characterized under pure tension, torsion, and combined (tension and torsion) loading. Three-dimensional digital image correlation using VIC-3D system was implemented to determine surface deformation patterns for identification of strain localizations. Neutron diffraction-based texture analysis is performed to obtain an understanding of the effect of loading path on the material texture compared with the as-received, initial grain orientation. Pole figures for Zr-702 tubes are obtained for each loading path.

The current generation of fully ceramic microencapsulated fuels, consisting of Tristructural Isotropic fuel particles embedded in a silicon carbide matrix, is fabricated by hot pressing. Matrix powder feedstock is comprised of alumina–yttria additives thoroughly mixed with silicon carbide nanopowder using polyethyleneimine as a dispersing agent. Fuel compacts are fabricated by hot pressing the powder–fuel particle mixture at a temperature of 1800–1900 °C using compaction pressures of 10–20 MPa. Detailed microstructural characterization of the final fuel compacts shows that oxide additives are limited in extent and are distributed uniformly at silicon carbide grain boundaries, at triple joints between silicon carbide grains, and at the fuel particle–matrix interface.

To investigate the mechanisms by which Y and La dopants affect the oxidation behavior of Ni-base single‐crystal superalloys, the oxide scales formed on two variants of a commercial X4 alloy, each with and without a MCrAlYHfSi coating were characterized. The alloy systems were oxidized for 100 h at 1100 °C and then examined using analytical transmission electron microscopy. Without a coating, a duplex scale was formed on the superalloy surface comprised of an outer Ni‐rich spinel‐type layer and an inner columnar α‐Al 2 O 3 layer. In this case, Hf and Ti were found segregated to the alumina grain boundaries in the outer part of the scale on both alloys but only Hf was detected near the metal–alumina interface. There was no evidence of Ta, Y or La segregation to the alumina scale grain boundaries after this exposure. The scale formed on the alloys with the thermally sprayed coating was primarily alumina, and Y and Hf segregated to the alumina grain boundaries for both alloys. There was evidence of Ti-rich oxides in the outer part of the scale indicating that Ti had diffused through the coating into the thermally grown oxide but La was not found.

A nanostructured ferritic alloy was irradiated with He+ to simulate service in a nuclear reactor and to test the hypothesis that the surface of nanoclusters is a preferential nucleation site for He bubbles. Transmission electron microscopy and atom probe tomography showed direct evidence of He bubble nucleation on the surfaces of nanoclusters and Ti(N,C) precipitates, and along grain boundaries and dislocations, thereby demonstrating an alloy design approach to improve the radiation tolerance of structural steels in the extreme environments found in nuclear reactors.

The roles of the alloying elements in three nanostructured ferritic alloys (14YWT, MA957 and Eurofer 97) have been established through the characterisation of the microstructure by atom probe tomography and spectrum imaging in a transmission electron microscope. Cr, W, Mo, Ti and Y were found in the ferrite matrix and contributed to solid solution hardening. Ti, Y, C, O and N were found in high number densities of precipitates and nanoclusters both in the grain interior and on grain boundaries and thereby contributed to precipitation hardening. Cr, W and Mo were enriched at the intraparticle regions of the grain boundaries. The solute segregation and precipitation pinned the grain boundaries and contributed to the excellent creep properties of the alloys.

This report details the findings of post-radiation mechanical testing and microstructural characterization performed on a series of model and commercial FeCrAl alloys to assist with the development of a cladding technology with enhanced accident tolerance. The samples investigated include model alloys with simple ferritic grain structure and two commercial alloys with minor solute additions. These samples were irradiated in the High Flux Isotope Reactor (HFIR) at Oak Ridge National Laboratory (ORNL) up to nominal doses of 7.0 dpa near or at Light Water Reactor (LWR) relevant temperatures (300-400 C). Characterization included a suite of techniques including small angle neutron scattering (SANS), atom probe tomography (APT), and transmission based electron microscopy techniques. Mechanical testing included tensile tests at room temperature on sub-sized tensile specimens. The goal of this work was to conduct detailed characterization and mechanical testing to begin establishing empirical and/or theoretical structure-property relationships for radiation-induced hardening and embrittlement in the FeCrAl alloy class. Development of such relationships will provide insight on the performance of FeCrAl alloys in an irradiation environment and will enable further development of the alloy class for applications within a LWR environment. A particular focus was made on establishing trends, including composition and radiation dose. Themore » report highlights in detail the pertinent findings based on this work. This report shows that radiation hardening in the alloys is primarily composition dependent due to the phase separation in the high-Cr FeCrAl alloys. Other radiation induced/enhanced microstructural features were less dependent on composition and when observed at low number densities, were not a significant contributor to the observed mechanical responses. Pre-existing microstructure in the alloys was found to be important, with grain boundaries and pre-existing dislocation networks acting as defect sinks, resulting in variations in the observed microstructures after irradiation. Dose trends were also observed, with increasing radiation dose promoting changes in the size and number density of the Cr-rich ' precipitates. Based on the microstructural analysis, performed tensile testing, and prior knowledge from FeCr literature it was hypothesized that the formation of the Cr-rich ' precipitates could lead to significant radiation-induced embrittlement in the alloys, and this could be composition dependent, a result which would mirror the trends observed for radiation-induced hardening. Due to the limited database on embrittlement in the FeCrAl alloy class after irradiation, a series of radiation experiments have been implemented. The overarching point of view within this report is the radiation tolerance of FeCrAl is complex, with many mechanisms and factors to be considered at once. Further development of the FeCrAl alloy class for enhanced accident tolerant applications requires detailed, single (or at least limited) variable experiments to fully comprehend and predict the performance of this alloy in LWRs. This report has been submitted as fulfillment of milestone M2FT-15OR0202321 titled, Summary report on the effect of composition on the irradiation embrittlement of Gen 1 ATF FeCrAl for the Department of Energy Office of Nuclear Energy, Advanced Fuel Campaign of the Fuel Cycle R&D program.« less

The High and Thermal Magnetic Processing/Electro-magnetic Acoustic Transducer (HTMP/EMAT) technology has been shown to be an enabling disruptive materials processing technology, that can achieve significant improvements in microstructure and consequently material performance beyond that achievable through conventional processing, and will lead to the next generation of advanced performance structural and functional materials. HTMP exposure increased the reaction kinetics enabling refinement of microstructural features such as finer martensite lath size, and finer, more copious, homogeneous dispersions of strengthening carbides leading to combined strength and toughness improvements in bainitic steels. When induction heating is applied in a high magnetic field environment, the induction heating coil is configured so that high intensity acoustic/ultrasonic treatment occurs naturally. The configuration results in a highly effective electromagnetic acoustical transducer (EMAT). HTMP combined with applying high-field EMAT, produce a non-contact ultrasonic treatment that can be used to process metal alloys in either the liquid state resulting in significant microstructural changes over conventional processing. Proof-of-principle experiments on cast irons resulted in homogeneous microstructures in small castings along with improved casting surface appearance. The experiment showed that by exposing liquid metal to the non-contact acoustic/ultrasonic processing technology developed using HMFP/EMAT wrought-like microstructures were developed in cast components. This Energymore » Intensive Processes (EIP) project sponsored by the DOE EERE Advanced Manufacturing Office (AMO) demonstrated the following: (1) The reduction of retained austenite in high carbon/high alloy steels with an ambient temperature HTMP process, replacing either a cryogenic or double tempering thermal process normally employed to accomplish retained austenite transformation. HTMP can be described as a 'heat-free', heat treating technology. Lower residual stresses in HTMP treated materials are anticipated since no thermal strains are involved in inducing the transformation of retained austenite to martensite in high alloy steel. (2) The simultaneous increase of 12% in yield strength and 22% in impact energy in a bainitic alloy using HTMP processing. This is a major breakthrough in materials processing for the next generation of structural materials since conventionally processed materials show a reduction in impact toughness with an increase in yield strength. HTMP is a new paradigm to beneficially increase both yield strength and impact energy absorption simultaneously. (3) HTMP processing refined both the martensite lath population and the carbide dispersion in a bainitic steel alloy during Gausstempering. The refinement was believed to be responsible for the simultaneous increase in strength and toughness. Hence, HTMP significantly impacts nucleation and growth phenomenon. (4) HTMP processing developed comparable ultimate tensile strength and twice the impact energy in a lower cost, lower alloy content ({approx}8% alloy content) steel, compared to highly alloyed, (31% alloy elements involving Ni, Co, and Mo) 250-grade margining steel. Future low-cost HTMP alloys appear viable that will exceed the structural performance of highly alloyed materials that are conventionally processed. This economic benefit will enable U.S. industry to reduce cost (better more competitive worldwide) while maintaining or exceeding current performance. (5) EMAT processed cast iron exhibits significantly higher hardness (by 51% for a 9T condition) than a no-field processed sample. (6) EMAT produced microstructures in cast iron resulted in an unique graphite nodule morphology, a modified pearlite content, and unique carbide types, that formed during solidification and cooling. (7) EMAT processed nanoparticle dispersions in Mg resulted in a very fine, unagglomerated distribution of the nanoparticles in the magnesium matrix. This provides a breakthrough technology to make the next generation of nanocomposite reinforced metal matrix composites which can be tailored to exhibit higher strength and ductility combinations not only at ambient temperature but at elevated temperatures where enhanced creep resistance is observed. This technology can be extended to non-metallic systems as long as a conductive containment vessel is utilized that will convey the EMAT signal into the material of interest during processing. (8) Facilitation of HTMP/EMAT technology commercialization, throughout the course of the project. Two technology limitations were overcome that led to the first generation commercial prototype HTMP/EMAT system which was initially installed at ORNL. (9) During this project, a production-scale equipment design to enable commercialization of HMFP technology was conceptualized, designed, fabricated, and installed at ORNL as a commercial-scale prototype system.« less

Extended abstract of a paper presented at Microscopy and Microanalysis 2013 in Indianapolis, Indiana, USA, August 4 – August 8, 2013.

Extended abstract of a paper presented at Microscopy and Microanalysis 2013 in Indianapolis, Indiana, USA, August 4 – August 8, 2013.

Extended abstract of a paper presented at Microscopy and Microanalysis 2012 in Phoenix, Arizona, USA, July 29 – August 2, 2012.

Extended abstract of a paper presented at Microscopy and Microanalysis 2011 in Nashville, Tennessee, USA, August 7–August 11, 2011.

Extended abstract of a paper presented at Microscopy and Microanalysis 2008 in Albuquerque, New Mexico, USA, August 3 – August 7, 2008

In recent years, Electron Beam Melting (EBM) has matured as a technology for additive manufacturing of dense metal parts. The parts are built by additive consolidation of thin layers of metal powder using an electron beam. With EBM, it is possible to create parts with geometries too complex to be fabricated by other methods, e.g. fine network structures and internal cavities. The process is run in vacuum, which makes it well suited for materials with a high affinity to oxygen, i.e. . titanium compounds. We present material data from a recently conducted study of how melt strategy affects EBM process for gamma titanium aluminide, Ti-48Al-2Cr-2Nb.The investigation includes microstructural characterization, grain size measurement and tensile testing.