In preparation for testing a lithium-helium heat exchanger at Sandia, unexpected rapid failure of the mild steel lithium preheater due to liquid metal embrittlement occurred when lithium at ~400 °C flowed into the preheater then at ~200 °C. This happened before the helium system was pressurized or heating with electron beams began. The paper presents an analysis of the preheater plus a discussion of some implications for fusion.
Drawn 304L stainless steel tubing was subjected to 42 different annealing heat treatments with the goal of initializing a microstructural model to select a heat treatment to soften the tubing from a hardness of 305 Knoop to 225–275 Knoop. The amount of recrystallization and grain size caused by 18 heat treatments were analyzed via optical microscopy and image analysis, revealing the full range of recrystallization from 0 to 100%. The formation of carbides during the longer duration and higher-temperature heat treatments was monitored via transmission electron microscope evaluation. The experimental results informed a model which includes recovery, recrystallization, and grain growth to predict microstructure and hardness. After initialization of the model, it was able to predict hardness with a R2 value of 0.95 and recrystallization with an R2 value of 0.99. The model was then utilized in the design and testing of a heat treatment to soften the tubing.
The goal of this LDRD project is to develop a rapid first-order experimental procedure for the testing of advanced cladding materials that may be considered for generation IV nuclear reactors. In order to investigate this, a technique was developed to expose the coupons of potential materials to high displacement damage at elevated temperatures to simulate the neutron environment expected in Generation IV reactors. This was completed through a high temperature high-energy heavy-ion implantation. The mechanical properties of the ion irradiated region were tested by either micropillar compression or nanoindentation to determine the local properties, as a function of the implantation dose and exposure temperature. In order to directly compare the microstructural evolution and property degradation from the accelerated testing and classical neutron testing, 316L, 409, and 420 stainless steels were tested. In addition, two sets of diffusion couples from 316L and HT9 stainless steels with various refractory metals. This study has shown that if the ion irradiation size scale is taken into consideration when developing and analyzing the mechanical property data, significant insight into the structural properties of the potential cladding materials can be gained in about a week.
In this project, we performed a preliminary set of sintering experiments to examine nanocrystal-enabled diffusion bonding (NEDB) in Ag-on-Ag and Cu-on-Cu using Ag nanoparticles. The experimental test matrix included the effects of material system, temperature, pressure, and particle size. The nanoparticle compacts were bonded between plates using a customized hot press, tested in shear, and examined post mortem using microscopy techniques. NEDB was found to be a feasible mechanism for low-temperature, low-pressure, solid-state bonding of like materials, creating bonded interfaces that were able to support substantial loads. The maximum supported shear strength varied substantially within sample cohorts due to variation in bonded area; however, systematic variation with fabrication conditions was also observed. Mesoscale sintering simulations were performed in order to understand whether sintering models can aid in understanding the NEDB process. A pressure-assisted sintering model was incorporated into the SPPARKS kinetic Monte Carlo sintering code. Results reproduce most of the qualitative behavior observed in experiments, indicating that simulation can augment experiments during the development of the NEDB process. Because NEDB offers a promising route to low-temperature, low-pressure, solid-state bonding, we recommend further research and development with a goal of devising new NEDB bonding processes to support Sandia's customers.
Fatigue cracking in metals has been and is an area of great importance to the science and technology of structural materials for quite some time. The earliest stages of fatigue crack nucleation and growth are dominated by the microstructure and yet few models are able to predict the fatigue behavior during these stages because of a lack of microstructural physics in the models. This program has developed several new simulation tools to increase the microstructural physics available for fatigue prediction. In addition, this program has extended and developed microscale experimental methods to allow the validation of new microstructural models for deformation in metals. We have applied these developments to fatigue experiments in metals where the microstructure has been intentionally varied.
We report here the fabrication processes used to manufacture US Party Team First Wall Qualification Mockups along with the detailed microstructural characterization and mechanical properties of the Be/CuCrZr/316L HIP bonds. A companion submission to this conference describes details of the PMTF heat flux testing and the performance of the first US FWQM.
Laser Engineered Net Shaping (LENS) is a novel manufacturing process for fabricating metal parts directly from Computer Aided Design (CAD) solid models. The process is similar to rapid prototyping technologies in its approach to fabricate a solid component by layer additive methods. However, the LENS technology is unique in that fully dense metal components with material properties similar to wrought materials can be fabricated. The LENS process has the potential to dramatically reduce the time and cost required realizing functional metal parts. In addition, the process can fabricate complex internal features not possible using existing manufacturing processes. The real promise of the technology is the potential to manipulate the material fabrication and properties through precision deposition of the material, which includes thermal behavior control, layered or graded deposition of multi-materials, and process parameter selection.