Publications

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The tungsten ITER divertor will be operated at temperatures above 1000 K. Most of the laboratory experiments on hydrogen isotope retention in tungsten have been performed at lower temperatures where the hydrogen is retained as both atoms and molecules. At higher temperatures, atomic trapping plays a smaller role. The purpose of this paper is to see if hydrogen is trapped at internal voids at elevated temperatures, and to see if gas-filled cavities can be formed at high fluences. Additionally, this paper examines the effect of helium bubbles and radiation damage on trapping. © 2010 Elsevier B.V. All rights reserved.

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Nano-structured palladium is examined as a tritium storage material with the potential to release beta-decay-generated helium at the generation rate, thereby mitigating the aging effects produced by enlarging He bubbles. Helium retention in proposed structures is modeled by adapting the Sandia Bubble Evolution model to nano-dimensional material. The model shows that even with ligament dimensions of 6-12 nm, elevated temperatures will be required for low He retention. Two nanomaterial synthesis pathways were explored: de-alloying and surfactant templating. For de-alloying, PdAg alloys with piranha etchants appeared likely to generate the desired morphology with some additional development effort. Nano-structured 50 nm Pd particles with 2-3 nm pores were successfully produced by surfactant templating using PdCl salts and an oligo(ethylene oxide) hexadecyl ether surfactant. Tests were performed on this material to investigate processes for removing residual pore fluids and to examine the thermal stability of pores. A tritium manifold was fabricated to measure the early He release behavior of this and Pd black material and is installed in the Tritium Science Station glove box at LLNL. Pressure-composition isotherms and particle sizes of a commercial Pd black were measured.

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Laser Engineered Net-shaping (LENS®) can directly manufacture near net shape metallic components from CAD files. The thermal history associated with LENS® process, which involves numerous reheating cycles, is critical to the microstructural evolution and mechanical properties of the LENS® fabricated parts. In this paper, the surface morphology of as-atomized PH13-8Mo steel powder is characterized; Variation of the height of deposited materials with process parameters is measured; Microhardness and tensile tests are carried out to evaluate the mechanical performance of LENS® deposited PH13-8Mo components; Microstructural analysis is conducted using OM, SEM, TEM to understand the microstructural evolution of the LENS® deposited PH13-8Mo samples; The thermal history and its effects on microstructural evolution and resultant mechanical properties is studied in order to understand the relationship between processing parameter, microstructure and mechanical properties of the LENS® fabricated PH13-8Mo components.

Laser Engineered Net Shaping{trademark} (LENS{reg_sign}) is a unique, layer additive, metal manufacturing technique that offers the ability to create fully dense metal features and components directly from a computer solid model. LENS offers opportunities to repair and modify components by adding features to existing geometry, refilling holes, repairing weld lips, and many other potential applications. The material deposited has good mechanical properties with strengths typically slightly higher that wrought material due to grain refinement from a quickly cooling weld pool. The result is a material with properties similar to cold worked material, but without the loss in ductility traditionally seen with such treatments. Furthermore, 304L LENS material exhibits good corrosion resistance and hydrogen compatibility. This report gives a background of the LENS process including materials analysis addressing the requirements of a number of different applications. Suggestions are given to aid both the product engineer and the process engineer in the successful utilization of LENS for their applications. The results of testing on interface strength, machinability, weldability, corrosion resistance, geometric effects, heat treatment, and repair strategy testing are all included. Finally, the qualification of the LENS process is briefly discussed to give the user confidence in selecting LENS as the process of choice for high rigor applications. The testing showed LENS components to have capability in repair/modification applications requiring complex castings (W80-3 D-Bottle bracket), thin wall parts requiring metal to be rebuilt onto the part (W87 Firing Set Housing and Y-12 Test Rings), the filling of counterbores for use in reservoir reclamation welding (SRNL hydrogen compatibility study) and the repair of surface defects on pressure vessels (SRNL gas bottle repair). The material is machinable, as testing has shown that LENS deposited material machines similar to that of welded metal. Tool wear is slightly higher in LENS material than in wrought material, but not so much that one would be concerned with increased tooling cost. The LENS process achieved process qualification for the AY1E0125 D-Bottle Bracket from the W80-3 LEP program, and in the effort, also underwent testing in weapons environments. These tests included structural dynamic response testing and drop testing. The LENS deposited parts were compared in these tests with conventionally machined parts and showed equivalency to such an extent that the parts were accepted for use in parallel path subsystem-level weapon environment testing. The evaluation of LENS has shown that the process can be a viable option when either complete metal parts are needed or existing metal parts require modification or repair. The LENS Qualification Technology Investment team successfully investigated new applications for the LENS process and showed that it has great applicability across the Nuclear Weapons Complex as well as in other high rigor applications.

The LENS Qualification team had the goal of performing a process qualification for the Laser Engineered Net Shaping{trademark}(LENS{reg_sign}) process. Process Qualification requires that a part be selected for process demonstration. The AY1E0125 D-Bottle Bracket from the W80-3 was selected for this work. The repeatability of the LENS process was baselined to determine process parameters. Six D-Bottle brackets were deposited using LENS, machined to final dimensions, and tested in comparison to conventionally processed brackets. The tests, taken from ES1E0003, included a mass analysis and structural dynamic testing including free-free and assembly-level modal tests, and Haversine shock tests. The LENS brackets performed with very similar characteristics to the conventionally processed brackets. Based on the results of the testing, it was concluded that the performance of the brackets made them eligible for parallel path testing in subsystem level tests. The testing results and process rigor qualified the LENS process as detailed in EER200638525A.

Laser Engineered Net Shaping{trademark} (LENS{reg_sign}) is a layer additive manufacturing process that creates fully dense metal components using a laser, metal powder, and a computer solid model. This process has previously been utilized in research settings to create metal components and new material alloys. The ''Qualification of LENS for the Repair and Modification of Metal NWC Components'' project team has completed a Technology Investment project to investigate the use of LENS for repair of high rigor components. The team submitted components from four NWC sites for repair or modification using the LENS process. These components were then evaluated for their compatibility to high rigor weapons applications. The repairs included hole filling, replacement of weld lips, addition of step joints, and repair of surface flaws and gouges. The parts were evaluated for mechanical properties, corrosion resistance, weldability, and hydrogen compatibility. This document is a record of the LENS processing of each of these component types and includes process parameters, build strategies, and lessons learned. Through this project, the LENS process was shown to successfully repair or modify metal NWC components.

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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.

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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.