Publications

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The effects of heat treatment parameters were examined in complex electrical contact alloys containing Pd-Ag-Cu-Au-Pt. These alloys (Paliney tradename, Deringer-Ney Inc., Bloomfield, CT) are strengthened by precipitation reactions. During processing such as glass-to-metal joining in hermetic connectors, if the cooling rate is too slow, discontinuous precipitation (DP) of lamellar 2nd phases can spoil the strengthening effect. Two different solutionizing temperatures were employed and the effects of cooling rates between 6 C/min and >200 C/min were studied. Novel metallographic techniques were developed to reveal the microstructure of these corrosion resistant alloys and quantitative image analysis (QIA) was used to determine the amount of 2nd phase precipitates. Vickers and Knoop microhardness testing was performed to determine the effects of heat treatment parameters on mechanical properties.

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The National Spent Nuclear Fuel Program, located at the Idaho National Laboratory (INL), coordinates and integrates national efforts in management and disposal of US Department of Energy (DOE)-owned spent nuclear fuel. These management functions include development of standardised systems for long-term disposal in the proposed Yucca Mountain repository. Nuclear criticality control measures are needed in these systems to avoid restrictive fissile loading limits because of the enrichment and total quantity of fissile material in some types of the DOE spent nuclear fuel. This need is being addressed by development of corrosion-resistant, neutron-absorbing structural alloys for nuclear criticality control. This paper outlines results of a metallurgical development programme that is investigating the alloying of gadolinium into a nickel-chromium-molybdenum alloy matrix. Gadolinium has been chosen as the neutron absorption alloying element due to its high thermal neutron absorption cross section and low solubility in the expected repository environment. The nickel-chromium-molybdenum alloy family was chosen for its known corrosion performance, mechanical properties, and weldability. The workflow of this programme includes chemical composition definition, primary and secondary melting studies, ingot conversion processes, properties testing, and national consensus codes and standards work. The microstructural investigation of these alloys shows that the gadolinium addition is present in the alloy as a gadolinium-rich second phase. The mechanical strength values are similar to those expected for commercial Ni-Cr-Mo alloys. The alloys have been corrosion tested with acceptable results. The initial results of weldability tests have also been acceptable. Neutronic testing in a moderated critical array has generated favourable results. An American Society for Testing and Materials material specification has been issued for the alloy and a Code Case has been submitted to the American Society of Mechanical Engineers for code qualification.

Laser Engineered Net Shaping (LENS) is being evaluated for use as a metal component repair/modification process for the NWC. An aspect of the evaluation is to better understand the characteristics of the interface between LENS deposited material and the substrate on which it is deposited. A processing and metallurgical evaluation was made on LENS processed material fabricated for component qualification tests. A process parameter evaluation was used to determine optimum build parameters and these parameters were used in the fabrication of tensile test specimens to study the characteristics of the interface between LENS deposited material and several types of substrates. Analyses of the interface included mechanical properties, microstructure, and metallurgical integrity. Test samples were determined for a variety of geometric configurations associated with interfaces between LENS deposited material and both wrought base material and previously deposited LENS material. Thirteen different interface configurations were fabricated for evaluation representing a spectrum of deposition conditions from complete part build, to hybrid substrate-LENS builds, to repair builds for damaged or re-designed housings. Good mechanical properties and full density were observed for all configurations. When tested to failure, fracture occurred by ductile microvoid coalescence. The repair and hybrid interfaces showed the same metallurgical integrity as, and had properties similar to, monolithic LENS deposits.

The National Spent Nuclear Fuel Program, located at the Idaho National Laboratory (INL), coordinates and integrates national efforts in management and disposal of US Department of Energy (DOE)-owned spent nuclear fuel. These management functions include development of standardized systems for long-term disposal in the proposed Yucca Mountain repository. Nuclear criticality control measures are needed in these systems to avoid restrictive fissile loading limits because of the enrichment and total quantity of fissile material in some types of the DOE spent nuclear fuel. This need is being addressed by development of corrosion-resistant, neutron-absorbing structural alloys for nuclear criticality control. This paper outlines results of a metallurgical development program that is investigating the alloying of gadolinium into a nickel-chromium-molybdenum alloy matrix. Gadolinium has been chosen as the neutron absorption alloying element due to its high thermal neutron absorption cross section and low solubility in the expected repository environment. The nickel-chromium-molybdenum alloy family was chosen for its known corrosion performance, mechanical properties, and weldability. The workflow of this program includes chemical composition definition, primary and secondary melting studies, ingot conversion processes, properties testing, and national consensus codes and standards work. The microstructural investigation of these alloys shows that the gadolinium addition is present in the alloy as a gadolinium-rich second phase. The mechanical strength values are similar to those expected for commercial Ni-Cr-Mo alloys. The alloys have been corrosion tested with acceptable results. The initial results of weldability tests have also been acceptable. Neutronic testing in a moderated critical array has generated favorable results. An American Society for Testing and Materials material specification has been issued for the alloy and a Code Case has been submitted to the American Society of Mechanical Engineers for code qualification.

The load relaxation behavior of small Elgiloy helical extension springs has been evaluated by a combined experimental and modeling approach. Isothermal, continuous heating, and interrupted heating relaxation tests of a specific spring design were conducted. Spring constants also were measured and compared with predictions using common spring formulas. For the constant heating rate relaxation tests, it was found that the springs retained their strength to higher temperatures at higher heating rates. A model, which describes the relaxation behavior, was developed and calibrated with the isothermal load relaxation tests. The model incorporates both time-independent deformation mechanisms, such as thermal expansion and shear modulus changes, as well as time-dependent mechanisms such as primary and steady state creep. The model was shown to accurately predict the load relaxation behavior for the continuous heating tests, as well as for a complex stepwise heating thermal cycle. The model can be used to determine the relaxation behavior for any arbitrary thermal cycle. An extension of the model to other spring designs is discussed.

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Solidification is an important aspect of welding, brazing, soldering, LENS fabrication, and casting. The current trend toward utilizing large-scale process simulations and materials response models for simulation-based engineering is driving the development of new modeling techniques. However, the effective utilization of these models is, in many cases, limited by a lack of fundamental understanding of the physical processes and interactions involved. In addition, experimental validation of model predictions is required. We have developed new and expanded experimental techniques, particularly those needed for in-situ measurement of the morphological and kinetic features of the solidification process. The new high-speed, high-resolution video techniques and data extraction methods developed in this work have been used to identify several unexpected features of the solidification process, including the observation that the solidification front is often far more dynamic than previously thought. In order to demonstrate the utility of the video techniques, correlations have been made between the in-situ observations and the final solidification microstructure. Experimental methods for determination of the solidification velocity in highly dynamic pulsed laser welds have been developed, implemented, and used to validate and refine laser welding models. Using post solidification metallographic techniques, we have discovered a previously unreported orientation relationship between ferrite and austenite in the Fe-Cr-Ni alloy system, and have characterized the conditions under which this new relationship develops. Taken together, the work has expanded both our understanding of, and our ability to characterize, solidification phenomena in complex alloy systems and processes.

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The weld solidification and cracking behavior of sulfur bearing free machining austenitic stainless steel was investigated for both gas-tungsten arc (GTA) and pulsed laser beam weld processes. The GTA weld solidification was consistent with those predicted with existing solidification diagrams and the cracking response was controlled primarily by solidification mode. The solidification behavior of the pulsed laser welds was complex, and often contained regions of primary ferrite and primary austenite solidification, although in all cases the welds were found to be completely austenite at room temperature. Electron backscattered diffraction (EBSD) pattern analysis indicated that the nature of the base metal at the time of solidification plays a primary role in initial solidification. The solid state transformation of austenite to ferrite at the fusion zone boundary, and ferrite to austenite on cooling may both be massive in nature. A range of alloy compositions that exhibited good resistance to solidification cracking and was compatible with both welding processes was identified. The compositional range is bounded by laser weldability at lower Cr{sub eq}/Ni{sub eq} ratios and by the GTA weldability at higher ratios. It was found with both processes that the limiting ratios were somewhat dependent upon sulfur content.

Laser deposits fabricated from two different compositions of 304L stainless steel powder were characterized to determine the nature of the solidification and solid state transformations. One of the goals of this work was to determine to what extent novel microstructure consisting of single-phase austenite could be achieved with the thermal conditions of the LENS [Laser Engineered Net Shape] process. Although ferrite-free deposits were not obtained, structures with very low ferrite content were achieved. It appeared that, with slight changes in alloy composition, this goal could be met via two different solidification and transformation mechanisms.