Additive Manufacturing for Energy Applications V: Properties, Performance Testing and Modeling I
Sponsored by: TMS Materials Processing and Manufacturing Division, TMS Structural Materials Division, TMS: Additive Manufacturing Committee, TMS: Nuclear Materials Committee
Program Organizers: Isabella Van Rooyen, Pacific Northwest National Laboratory; Subhashish Meher, Pacific Northwest National Laboratory; Xiaoyuan Lou, Purdue University; Kumar Sridharan, University of Wisconsin-Madison; Michael Kirka, Oak Ridge National Laboratory; Yi Xie, Purdue University
Tuesday 8:00 AM
March 21, 2023
Room: 23A
Location: SDCC
Session Chair: Kumar Sridharan, University of Wisconsin-Madison
8:00 AM Introductory Comments
8:05 AM Invited
Irradiation Response and Mechanical Property Changes of Conventionally and Additively Manufactured 316L Stainless Steels: Lin Shao1; 1Texas A&M University
Our recent studies on irradiation responses and mechanical properties of AM 316L stainless steels were reviewed. The major findings include: (1) printing-introduced large pores contain amorphous cores. The pore edges develop either island-like segregation or layered shell-like structures; (2) residual stress can be effectively removed by applying annealing; (3) proton irradiation induces complicated dislocation networks and short-range ordering around dislocations; (4) deformation has a transition from dislocation gliding to twinning as a function of damage levels; (5) the deformation mechanism change is caused by irradiation hardening which allows the yielding stress high enough to exceed the required shear stress for twinning nucleation and activation; (6) twinning benefits the homogeneity in plasticity flow; (7) both high angle grain boundaries and cell walls exhibit defect sink property, but high angle grain boundaries are more efficient; (8) the irradiation-induced swelling in AM variants is systematically less than the wrought counterpart.
8:40 AM
Creep Behavior of an Additively Manufactured Al-Ce-Ni-Mn-Zr Alloy: Sumit Bahl1; Richard Michi1; Jonathan Poplawsky1; Lawrence Allard1; Kevin Sisco2; Ryan Dehoff1; Alex Plotkowski1; Amit Shyam1; 1Oak Ridge National Laboratory; 2University of Tennessee-Knoxville
Additive manufacturing has enabled the development of higher-temperature aluminum alloys for use in the 250 – 400 °C temperature range. A new Al-Ce-Ni-Mn-Zr alloy is designed and fabricated with laser powder bed fusion additive manufacturing. The as-fabricated alloy exhibits excellent creep resistance in the 300 – 400 °C temperature range. Aging the alloy precipitates nanoscale L12-Al3Zr particles which strengthen the alloy at ambient temperature. However, the alloy exhibits similar creep strain rates in the as-fabricated and peak-aged conditions indicating an unexpected lack of strengthening from nanoscale Al3Zr precipitates at elevated temperatures (300 – 400 °C). Informed by microstructural characterization performed using scanning transmission electron microscopy and atom probe tomography, this presentation will discuss creep deformation mechanisms in the Al-Ce-Ni-Mn-Zr alloy to help explain lack of strengthening from Al3Zr precipitates.
9:00 AM
Creep of Wire Arc Additive Manufactured Stainless Steels for Power Generation Applications: Juan Gonzalez1; Luc Hagen1; Stephen Tate1; Jonah Klemm-Toole1; 1Colorado School of Mines
Austenitic stainless steels are commonly used in power generation and other high-temperature structural applications that are subjected to elevated temperatures over long service lives. Precipitation of embrittling phases such as sigma, represents one of the potential degradation mechanisms austenitic stainless steels, leading to the deterioration of mechanical properties during service. Understanding the impact of the wire arc additive manufacturing process (WAAM) on the formation of sigma phases on austenitic stainless steels will help implement WAAM as a reliable method for advanced manufacturing of power generation components. In this presentation, we will discuss the influences of sigma phase formation, as well as feedstock composition, on the creep behavior of wire arc additive manufactured stainless steels such 316L, 316LSi, 316H, and 16-8-2 at 650 °C. The creep behavior of WAAM samples is compared to wrought forms to provide insight into the outlook of using WAAM for high temperature structural components.
9:20 AM
Creep Properties of Additively Manufactured 316L Stainless Steel: Performance and Microstructure: Xuan Zhang1; Wei-Ying Chen1; Chris Carter1; Jun-Sang Park1; Peter Kenesei1; Aniket Tekawade1; Yashas Satapathy1; Meimei Li1; 1Argonne National Laboratory
Time-dependent properties such as creep properties are critical for structural materials’ applications in certain energy sectors such as nuclear. Due to the unique microstructures, adopting additively manufactured (AM) alloys requires new creep data to be collected before qualification and implementation. In this talk, a set of creep data on AM 316L stainless steel manufactured by the laser powder bed fusion will be presented, as well as the deformation microstructures characterized by optical and electron microscopy techniques. In addition, synchrotron high-energy x-ray tomography has been used to measure the pores and/or cracks inside the test specimens before and after deformation. New developments in tomography data analysis, using advanced computing algorithms including convolutional neutron networks, have been implemented to directly reduce raw detector data into explicit pore/crack shape representations for quantitative measurements. Together, the microstructural information provided a rationale for the creep performance of the AM 316L stainless steel.
9:40 AM Break
9:55 AM
Creep Resistance and Microstructure of Binary Al-Ce Alloy Produced by Casting and Laser Powder Bed Fusion: Jillian Stinehart1; Le Zhou1; 1Marquette University
Al-Ce based alloys have shown promise as next-generation lightweight high temperature aluminum alloys. The goal of this study is to explore the creep property and creep deformation mechanisms in binary Al-Ce alloys to provide a benchmark for future alloy development. Binary Al-10Ce alloys are manufactured by laser powder bed fusion (LPBF) and casting. The porosity, eutectic lamellae and grain structure are characterized by microtomography, optical and scanning electron microscope. The as-built LPBF alloy consisted of a much finer eutectic lamellar microstructure and showed improved room-temperature strength and ductility compared to the as-cast alloy. Creep resistance was measured in compression and tension at temperatures between 250-400°C. The steady-state creep strain rate, post microstructure and fracture morphology were determined and analyzed to reveal the creep deformation mechanisms. The effect of the eutectic morphology on the creep resistance for LPBF and cast alloys will be compared and discussed.
10:15 AM Invited
The Key Role of High-Temperature Testing & Post-Test Characterization to Qualify Advanced Manufacturing Methods and Materials for Energy Applications: John Shingledecker1; David Gandy1; Alex Bridges1; 1EPRI
The Electric Power Research Institute (EPRI)'s Advanced Manufacturing Methods & Materials (AM3) Initiative is aimed at accelerating the application of advanced and additive manufacturing into new and developing energy systems including small modular reactors, advanced reactors, concentrating solar power plants, supercritical CO2 cycles, and low-carbon fueled combined cycle plants. Accelerated qualification requires codes & standards development, joint industry qualification activities, demonstrations, and collaborative supply chain engagement. This talk will focus on the importance of relevant high-temperature testing and post-test characterization as foundational to these activities. Topics covered will include: the performance of stainless steel and nickel-based alloy diffusion bonded compact heat exchangers in the creep regime, additively manufactured superalloy gas turbine guide vanes and opportunities for further improvement, and progress on the evaluation of directed energy deposition stainless steel valve bodies and pressure retention components for nuclear reactors and other energy applications which will require code approvals.
10:50 AM
High Temperature Tribology of AM Ni-based Alloys 699XA and 400: Emma White1; Beyza Oeztuerk1; Mathias Galetz1; 1DECHEMA Forschungsinstitut
Understanding the high temperature tribological behavior of materials is crucial for applications in the aerospace, transportation, and energy generation industries. The friction and wear behavior of conventionally processed and additively manufactured (AM) Ni-based alloys 699XA and 400 was investigated by pin-on-disk tribotesting against an alumina counterpart at room temperature and up to 600°C in air. The wear tracks were examined using optical microscopy, scanning electron microscopy, profilometry and Raman spectroscopy on the surface and in cross-section. The microstructures and surface oxides of the conventional versus AM alloys are compared and correlated to the friction coefficients and wear rates as a function of temperature. The trends are discussed in terms of their mechanisms and the potential for improving the wear behavior of these types of Ni-based alloys. This ‘topAM’ has project received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 958192.
11:10 AM Cancelled
Nanomechanical Properties of Heat-Treated High Entropy Alloys: Modupeola Dada1; Patricia Popoola1; Evlly Mtileni1; Lindokuhle Ntanzi1; 1Tshwane University of Technology
The mechanical properties of High entropy alloys fabricated via arc melting have been widely studied in the literature. However, the investigation into the influence of heat treatment on the nanomechanical performance and deformation behaviour of arc-melted high entropy alloys remains limited. In this study, the elastic modulus, hardness and creep at room temperature of AlCuFeNiSi high entropy alloys via arc melting were explored using a Nano indenter before and after heat treatment as metal hydrides for energy storage applications. The heat-treated high entropy alloys showed a 10% improvement in hardness and 23% increment in elastic modulus compared with the as-cast high entropy alloys at 200 mN applied load attributed to the significant grain refinement. However, a slight reduction in the creep resistance was observed.