bluuebunny/crossref_metadata_2025 huggingface dataset:
Acceleration of Material Acceptance and Industry Adoption of an Additively Manufactured Nickel-base Superalloy
Authors: Bridges Alex , Shingledecker John , Hussain Zara , Forster Jon , Nemeth Andre , Vogel Greg , O’Nora Nathan
Published: October 2024

The power industry has been faced with continued challenges around decarbonization and additive manufacturing (AM) has recently seen increased use over the last decade. The use of AM has led to significant design changes in components to improve the overall efficiency of gas turbines and more recently, hot-section components have been fabricated using AM nickel-base superalloys, which have shown substantial benefits. This paper will discuss and summarize extensive studies led by EPRI in a novel AM nickel-base superalloy (ABD·900-AM). A comprehensive high temperature creep testing study including >67,000 hours of creep data concluded that ABD-900AM shows improved properties compared to similar ~35% volume fraction gamma prime strengthened nickel-base superalloys fabricated using additive methods. Several different creep mechanisms were identified and various factors influencing high temperature behavior, such as grain size, orientation, processing method, heat treatment, carbide structure, chemistry and porosity were explored. Additional studies on the printability, recyclability of powder, wide range of process parameters and several other factors have also been studied and results are summarized. A summary on the alloy -by-design approach and accelerated material acceptance of ABD-900AM through extensive testing and characterization is further discussed. Numerous field studies and examples of field use cases in ABD-900AM are also evaluated to showcase industry adoption of ABD-900AM.
Experimental and Numerical Characterization of High Temperature Deformation Behavior of 347H Stainless Steel
Authors: Joy Jobin K. , Rovinelli A. , Arul Kumar M. , Lebensohn R.A. , Capolungo L. , Ren Q.Q. , Yamamoto Y. , Poplawsky J.D. , Detrois M. , Jablonski P.
Published: October 2024

This study investigates how temperature affects the plasticity and thermal creep behavior of 347H stainless steel under uniaxial tension. The research combined experimental testing with advanced computational modeling. Two types of experiments were conducted: uniaxial tensile tests at temperatures from 100°C to 750°C using strain rates of ~10⁻⁴ s⁻¹, and creep tests at temperatures between 600°C and 750°C under various stress levels. These experimental results were used to develop and validate a new integrated mechanistic model that can predict material behavior under any loading condition while accounting for both stress and temperature effects. The model was implemented using a polycrystalline microstructure simulation framework based on elasto-viscoplastic Fast Fourier Transform (EVPFFT). It incorporates three key deformation mechanisms: thermally activated dislocation glide, dislocation climb, and vacancy diffusional creep. The model accounts for internal stress distribution within single crystals and considers how precipitates and solute atoms (both interstitial and substitutional) affect dislocation movement. After validation against experimental data, the model was used to generate Ashby-Weertman deformation mechanism maps for 347H steel, providing new insights into how microstructure influences the activation of different creep mechanisms.
Surface Characterization of Laser Clad Surfaces using Profile and Arial Techniques
Authors: Mandal Rahul , Cavill Simon , Bloomer Stephen , Carpenter Charles , Baufeld Bernd
Published: October 2024

Diode laser cladding (DLC) surfaces, valued in the nuclear industry for their wear resistance, corrosion protection, and oxidation resistance, present unique challenges in surface characterization compared to conventionally machined surfaces. While traditional machined surfaces exhibit predictable, periodic topographies that can be validated through simple linear profile measurements, DLC surfaces feature distinctive metal tracks with central peaks and inter-track troughs, creating a wave-like structure with randomly distributed spherical asperities. This complex topography cannot be adequately characterized by traditional single-trace sampling methods due to significant variations in localized features at peaks and troughs. To address this challenge, this study examines DLC surfaces produced under varying control parameters (laser power, head travel speed, powder feed rate, and track offset) using laser confocal microscopy. Both profile and areal surface measurements are compared to identify the most effective method for characterizing DLC surface structure and quality, providing a foundation for standardized quality assessment in industrial applications.
PAW and GTAW Welding Repair of HP/IP and Generator Rotors of a Steam Turbine for Electric Power Generation
Authors: Gómez Flórez Pablo Andrés , Betancur Alejandro Toro , Morales Galeano John Edison , Velásquez Jeisson Mejía
Published: October 2024

This work describes the repair procedure conducted on the High Pressure/Intermediate Pressure (HP/IP) and generator rotors of a 180 MW steam turbine General Electric (GE) - STAG207FA type D11 installed at La Sierra Thermoelectric Power Plant in Puerto Nare, Colombia. A lubricant supply failure at base load caused severe adhesive damage to the shafts in the bearing support areas and a permanent 3.5 mm bow at the HP/IP rotor mid span section, which required a complex intervention. The repair process began with the identification of the rotors manufacturing material through in-situ metallographic replicas, handheld XRF analysis and surface hardness measurements. Volumetric manual Gas Tungsten Arc Welding (GTAW) welding reconstruction of cracked areas followed by a surface overlay using GTAW and Plasma Arc Welding (PAW) welding processes were applied with a modular mechanized system, where a stress relief treatment through vibration was implemented with the help of computational simulations carried out to determine the fundamental frequencies of the rotors. Geometric correction of the HP/IP rotor mid span section was achieved thanks to the excitation of the rotor at some fundamental frequencies defined by the dynamic modeling and the use of heat treatment blankets at specific locations as well. Finally, after machining and polishing procedures, the power unit resumed operation eleven months after the failure and remains in service to the present date.
Life Extension of Gas Turbine Blades Made from Nickel-Based Superalloys
Authors: Gowreesan Vamadevan , Greaves Wayne
Published: October 2024

Gas turbine blades made from nickel-based superalloys, valued for their high temperature stability and creep resistance, undergo various forms of microstructural degradation during extended service at elevated temperatures that can ultimately lead to blade failure. To extend blade and turbine rotor life, Sulzer has developed evaluation and rejuvenation processes that include microstructural assessment and stress rupture testing of specimens from service-exposed blades. While stress rupture testing presents certain limitations and challenges in evaluating material condition, Sulzer has successfully rejuvenated hundreds of gas turbine blade sets across multiple superalloy types, including GTD 111, IN 738 LC, and U 500, demonstrating the effectiveness of heat treatment rejuvenation in improving microstructure and mechanical properties of service-degraded components.
Assessment of Cracking and Strain Monitoring of a Grade 92 Pipe from a Heat Recovery Steam Generator
Authors: Han Su Ji , Lee Han-sang , Jung Jinesung , Lee Gil Jae , Park Jin-Geun , Lee Seung Wook
Published: October 2024

In flexible operation with increased number of startup, shutdown, and load fluctuations, thermal fatigue damage is exacerbated along with existing creep damage in power plant pipe and pressure vessels. Recently, cracks were found in the start-up vent pipe branching from the reheat steam pipe within a heat recovery steam generator(HRSG) of J-class gas turbine, occurring in the P92 base material and repair welds. This pipe has been used at the power plant for about 10 years. Microstructural analysis of the cross-section indicated that the cracks were primarily due to thermal fatigue, growing within the grains without changing direction along the grain boundaries. To identify the damage mechanism and evaluate the remaining life, temperature and strain monitoring were taken from the damaged piping during startup and normal operation.
Creep Crack Growth on High and Low Creep Ductility Grade 91 Steel
Authors: Hanes Troy , Stephens Robert , Siefert John , Perrin Ian
Published: October 2024

This research compares creep crack growth behavior of two heats of creep strength enhanced ferritic (CSEF) steel, grade 91. These heats represent extremes of creep damage susceptibility, one heat exhibiting low creep ductility and the other high creep ductility. Creep crack growth tests were performed with compact tension specimens and were monitored with direct current potential drop and optical surface measurements. Load line displacement was measured throughout the duration of the tests. Specimens were sectioned, mounted, and analyzed using optical and scanning electron microscopy to assess the presence of oxidation, micro-cracking, creep damage, and void density. Tests were performed over a range of initial stress intensities on the low ductility material to investigate the impact of creep ductility. Metallurgical evidence and test data for each crack growth test was assessed to evaluate crack growth behavior linked to creep crack growth parameter (C*) and stress/creep damage distribution in the vicinity of the crack.
Impact of Three Additive Manufacturing Techniques on Microstructure and Creep Damage Development in Alloy 718
Authors: Harless Nikki , Shingledecker John , Stoodt Kyle , Cwiok Kevin , Kulkarni Anand
Published: October 2024

Inconel 718 is a nickel-based superalloy known for its excellent combination of high-temperature strength, corrosion resistance, and weldability. Additive Manufacturing (AM) has revolutionized traditional manufacturing processes by enabling the creation of complex and customized components. In this work, three prominent AM techniques: Laser-Based Powder Bed Fusion (PBF), Wire Direct Energy Deposition (DED), and Binder Jet (BJ) processes were explored. A thorough metallographic analysis and comparison of samples was conducted after short-term creep testing originating from each of the three aforementioned techniques in addition to wrought material. Detailed electron microscopy unveiled equiaxed grains in both BJ and wrought samples while PBF samples displayed elongated finer grain structures in the build direction, characteristic of PBF. The DED samples revealed a more bimodal grain distribution with a combination of smaller equiaxed grains accompanied by larger more elongated grains. When assessing the three processes, the average grain size was found to be larger in the BJ samples, while the PBF samples exhibited the most significant variation in grain and sub-grain size. Number density, size, and shape of porosity varied between all three techniques. Post-creep test observations in PBF samples revealed the occurrence of wedge cracking at the failure point, accompanied by a preference for grain boundary creep void formation while BJ samples exhibited grain boundary creep void coalescence and cracking at the failure location. In the DED samples, void formation was minimal however, it seemed to be more prevalent in areas with precipitates. In contrast, the wrought sample showed void formation at the failure site with a preference for areas with primary carbide formation. Despite BJ samples demonstrating similar or even superior rupture life compared to other AM techniques, a noteworthy reduction in rupture ductility was observed. While a coarse, uniform grain size is generally linked to enhanced creep resistance and rupture life, the combination of pre-existing voids along grain boundaries and the formation of new voids is hypothesized to accelerate rapid fracture, resulting in diminished ductility. This research shows careful consideration is needed when selecting an AM technology for high- temperature applications as creep behavior is sensitive to the large microstructural variations AM can introduce.
Evaluating Quality of Diffusion Bonded Material through Microscopy Measurement of Bondline Grain Growth
Authors: Jentz Ian , Desorcy Lukas , Bollinger Andrea
Published: October 2024

Simple and effective material examination methods are desired for the diffusion bonding process, so that bonding produced components, such as compact heat exchangers, can be used in nuclear applications. Optical microscopy of diffusion bond process samples is a quick way to examine diffusion bond-line microstructure and to evaluate material quality. The stacked nature of a diffusion bonded-block results in distinct regions of grain growth both at and away from the bond interface. Strong diffusion bond materials exhibit grain growth across the original bond interface plane, weak materials have little-to-no growth across. A series of 316H diffusion bonded specimens of differing quality and strength were examined using optical microscopy. The microstructure both at and away from the bond interface was examined over 15mm long sections of the bond-line. A metric for evaluating bond growth is proposed. This is defined as the Bond Line Growth Threshold (BLGT) and is evaluated as the percentage of the bond line with grains meeting the threshold. Here a fraction of the diffusion bond is considered bonded when its grains exceed a threshold of growth past the bond interface. The BLGT is determined through automated image processing methods.
Material Synthesis and Advanced Manufacturing Without Melting: Advantages of Bulk, High-Shear Processing
Authors: Komarasamy Mageshwari , Grant Glenn
Published: October 2024

The next generation of materials and assemblies designed to address challenges in power generation, such as molten salt or supercritical carbon dioxide thermal transfer systems, corrosion, creep/fatigue, and higher temperature operation, will likely be highly optimized for their specific performance requirements. This optimization often involves strict control over microstructure, including homogeneity, grain size, texture, and grain boundary phases, as well as precise alloy chemistry and homogeneity. These stringent requirements aim to meet the new demands for bulk mechanical performance and durability. Some advanced materials, like oxide-dispersion strengthened or high-entropy alloys, necessitate specialized synthesis, fabrication, or welding/joining processes. Traditional methods that involve melting and solidifying can compromise the optimized microstructure of these materials, making non-melting synthesis and fabrication methods preferable to preserve their advanced characteristics. This paper presents examples where solid-phase, high-shear processing has produced materials and semi-finished products with superior performance compared to those made using conventional methods. While traditional processing often relies on thermodynamics-driven processes, such as creating precipitate phases through prolonged heat treatment, high-shear processing offers kinetics-driven, non-equilibrium alternatives that can yield high-performance microstructures. Additionally, examples are provided that demonstrate the potential for more cost-effective manufacturing routes due to fewer steps or lower energy requirements. This paper highlights advances in high-shear extrusion processing, including friction extrusion and shear-assisted processing and extrusion, as well as developments in solid-phase welding techniques like friction stir welding for next-generation power plant materials.
Wire Arc Additive Manufacturing of Creep Strength Enhanced Ferritic Steels and Nickel Alloys
Authors: Krein Ronny , Sushko Vadym
Published: October 2024

Additive manufacturing is a groundbreaking manufacturing method that enables nearly lossless processing of high-value materials and produces complex components with a level of flexibility that traditional methods cannot achieve. Wire arc additive manufacturing (WAAM), utilizing a conventional welding process such as gas metal arc welding, is one of the most efficient additive manufacturing technologies. The WAAM process is fully automated and guided by CAD/CAM systems on robotic or CNC welding platforms. This paper explores the fundamental concepts and metallurgical characteristics of WAAM. It focuses primarily on the mechanical properties of printed sample structures made from P91, X20, and alloys 625 and 718 wire feedstock. The study particularly addresses the anisotropy of mechanical properties through both short-term and long-term testing, comparing these results to materials processed using conventional methods.
Fatigue Properties of High-Performance Ferritic (HiperFer) Steels
Authors: Kuhn  , Bernd  , Fischer  , Torsten
Published: October 2024

High-performance Ferritic (HiperFer) steels represent a promising materials innovation for next-generation thermal energy conversion systems, particularly in cyclically operating applications like concentrating solar thermal plants and heat storage power plants (Carnot batteries), where current market adoption is hindered by the lack of cost-effective, high-performance materials. HiperFer steels demonstrate superior fatigue resistance, creep strength, and corrosion resistance compared to conventional ferritic-martensitic 9-12 Cr steels and some austenitic stainless steels, making them potentially transformative for future energy technologies. This paper examines the microstructural mechanisms underlying HiperFer’s enhanced fatigue resistance in both short and long crack propagation, while also presenting current findings on salt corrosion properties and exploring potential alloying improvements for fusion reactor applications, highlighting the broad technical relevance of these innovative materials.
Creep Property of Long-term Service Exposed T23-347H Dissimilar Welded Joint
Authors: Lee Seung Wook , Lee Han-sang , Han Ji
Published: October 2024

This study conducted creep tests, microstructural, and hardness analyses on SA213T23-TP347H dissimilar weld joints of long-term serviced coal-fired boiler final superheater tube. The welded joint (SA213 T23-TP347H) of the superheater tube, after approximately 105,000 hours of service, was sampled for creep life assessment and maintenance planning. Creep tests were conducted at 600°C under three stress conditions: 100, 140, and 160MPa. Most cracks were observed in the heat-affected zone of T23, and compared to unused tubes, the creep life consumption rate was approximately 90%. All dissimilar weld joints used welding rods similar in chemical composition to T23, and significant hardness reduction occurred in the flame-affected zone.
A Novel in Situ Miniature Creep Tester for Evaluation of New Cladding Alloys
Authors: Lima Lucas Maciel de Andrade , Hassan Tasnim
Published: October 2024

Miniature specimen tests are necessary to assess the mechanical properties of new fuel cladding alloys for next-generation nuclear reactors. The small specimen allows for extensive testing programs from limited volumes of material. However, there is a lack of testing equipment to perform high-temperature mechanical tests on the miniature specimen. This work presents the development of a high-temperature creep test system for miniature specimens with in situ scanning electron microscope (SEM) testing capability for real-time characterization. Here, we discuss the challenges of the development of the system, such as gripping the samples, loading, heating, cooling mechanisms, and strain measurement. The equipment is used to investigate the creep behavior of FeCrAl alloy Kanthal APMT, and the results are compared with conventional creep test data from the same batch of this material.
Effect of Manufacturing Process Parameters on Long-Term Microstructural Evolution and Accumulation of Creep Damage in Grade 91 Material
Authors: Ortolani M. , Locatelli R. , Siefert J. , Bridges A.
Published: October 2024

Grade 91 creep strength-enhanced ferritic steel is a critical material in power generation, widely used for high-temperature, high-pressure tubing and piping applications. Its superior elevated-temperature strength derives from a distinctive microstructure of tempered martensite with uniformly dispersed secondary phases (carbides and carbo-nitrides). This microstructure, crucial for reliable service performance, is achieved through precise control of the manufacturing process, including steelmaking, hot forming, and final heat treatment. This investigation builds upon earlier research into the relationship between manufacturing parameters and short-term creep-rupture properties in T91 tubes, and a recent update that included test results exceeding 30,000 hours. This study presents a comprehensive metallurgical analysis of ruptured test specimens. The investigation focuses on correlating manufacturing parameters with not only creep strength but also material ductility and microstructural evolution during long-term exposure, providing valuable insights into the material’s behavior under extended service conditions.
Improvements in Creep Ductility of the UK Cast MarBN Steel, IBN-1
Authors: Lockyer Scott , Roberts Steve , Strangwood Martin , Qi Jiahui , Thandi Simran , Davis Sam , Jepson Mark A. E.
Published: October 2024

MarBN steels, originally developed by Professor Fujio Abe at NIMS Japan, have undergone significant advancement in the UK through a series of government-funded collaborative projects (IMPACT, IMPEL, INMAP, IMPULSE, and IMPLANT). These initiatives have achieved several major milestones, including operational power plant trials, full-scale extruded pipe production, matching welding consumable development, and most notably, the creation of IBN-1—a new steel demonstrating 30-45% higher creep strength than Grade 92. However, like other creep strength-enhanced ferritic steels, IBN-1 shows reduced creep ductility under the lower stress conditions typical of operational use. Since adequate creep ductility is essential for component damage tolerance and effective in-service monitoring, this study investigates the effects of an alternative normalizing and tempering heat treatment on cast IBN-1. The research presents creep rupture test results showing improved ductility and analyzes the microstructural mechanisms responsible for this enhancement.
Off-Stoichiometric Effect on Properties of TiC
Authors: Matsuura Hiromu , Hoshizaki Kotaro , Ida Shuntaro , Yoshimi Kyosuke
Published: October 2024

Titanium carbide (TiC) have a wide off-stoichiometric composition when in equilibrium with the metallic phase. In this case, the off-stoichiometric effect allows the substitution of other transition metals (TM) at the Ti site and vacancy formation at the C site. It leads to changes in the material properties of TiC. Therefore, it is important to investigate the change of material properties with the off-stoichiometric effect. In this study, the elastic properties of (Ti, TM)Cx were focused on. To investigate the change of elastic properties with various transition metals substitution, elastic properties were evaluated by first-principles calculations. From the calculation, it was suggested that bulk modulus is controlled by the 1st and 2nd nearest neighbor bond, but shear modulus is mainly affected by only the 1st nearest neighbor bond. Therefore, it was indicated that proper control of the fraction of transition metals and vacancy could be possible for designing (Ti.TM)Cx with high strength and toughness.
Nickel Superalloy Composition and Process Optimization for Weldability, Cost, and Strength
Authors: Mehl Sophie , Cole Anna , Olson Tanner , Sanders Paul , Shingledecker John , Zhang Shutong
Published: October 2024

Advanced power generation systems, including advanced ultrasupercritical (A-USC) steam and supercritical carbon dioxide (sCO2) plants operating above 700°C, are crucial for reducing carbon dioxide emissions through improved efficiency. While nickel superalloys meet these extreme operating conditions, their high cost and poor weldability present significant challenges. This study employs integrated computational materials engineering (ICME) strategies, combining computational thermodynamics and kinetics with multi-objective Bayesian optimization (MOBO), to develop improved nickel superalloy compositions. The novel approach focuses on utilizing Ni3Ti (η) phase strengthening instead of conventional Ni3(Ti,Al) (γ’) strengthening to enhance weldability and reduce costs while maintaining high-temperature creep strength. Three optimized compositions were produced and experimentally evaluated through casting, forging, and rolling processes, with their microstructures and mechanical properties compared to industry standards Nimonic 263, Waspaloy, and 740H. Weldability assessment included solidification cracking and stress relaxation cracking tests, while hot hardness measurements provided strength screening. The study evaluates both the effectiveness of the ICME design methodology and the practical potential of these cost-effective η-phase strengthened alloys as replacements for traditional nickel superalloys in advanced energy applications.
Damage Mechanisms - Failure Analysis of Cracked 304 Stainless Steel Conduit of PWR Incore Instrumentation System
Authors: Mejia Alejandro , Martin Richard , Lu Hui
Published: October 2024

The incore instrumentation system of a pressurized water reactor (PWR) facilitates neutron flux mapping and temperature measurements at specific core locations. A guide conduit, extending from the seal table to the lower reactor pressure vessel head, guides and protects each incore guide thimble between the table and the lower reactor vessel head. Each flux thimble houses a detector and drive cable. Once filled with reactor coolant, the conduit becomes an extension of the reactor coolant pressure boundary. This paper reports the examination results of cracking detected in a TP304 stainless steel guide conduit adjacent to a fillet weld at the upper surface of a TP304 seal table. The cracking resulted in reactor coolant leakage that was detected by the presence of boric acid deposits on the exterior of the conduit and table. Failure analysis including dimensional measurements, chemical analysis, stereomicroscopy, metallography, and scanning electron microscopy showed that extensive cracking of the conduit and seal table material occurred due to stress corrosion cracking (SCC). Assessment showed that chlorine-containing deposits were present on the exterior of the conduit and on the surfaces of the seal table and were due to the design and operation of HVAC systems at the coastal plant. Stainless steels are susceptible to SCC in environments with elevated temperatures, chloride contents, and increased tensile stress – particularly in non-post weld heat treated (PWHT) weld regions and the heat affected zone (HAZ). This was the apparent primary cause of the failure. However, chloride-induced SCC of such materials typically results in transgranular crack propagation, whereas the observed cracks were indicative of intergranular stress corrosion cracking (IGSCC). Microstructural analysis showed that the observed cracks initiated in sensitized areas of material adjacent to the weld. Sensitization of the material caused chromium depletion from adjacent areas and increased susceptibility of the depleted areas to IGSCC. In this case, the most probable source of sensitization was related to welding and the long-term growth of grain boundary carbides nucleated during welding. This was considered a contributing cause to the failure.
Microstructural Models for the Creep Strength and Ductility of Diffusion-Bonded 316H Steel
Authors: Bhatt Sagar , Messner Mark C. , Wang Rui , Gao Fei
Published: October 2024

Diffusion bonded compact heat exchangers have exceptionally high heat transfer efficiency and might significantly improve the performance and reduce the cost of supercritical carbon-dioxide Brayton cycle power plants using high temperature heat sources, like high temperature nuclear reactors and concentrating solar power plants. While these heat exchangers have an excellent service history for lower temperature applications, considerable uncertainty remains on the performance of diffusion bonded material operating in the creep regime. This paper describes a microstructural modeling framework to explore the plausible mechanisms that may explain the reduced creep ductility and strength of diffusion bonded material, compared to wrought material. The crystal plasticity finite element method (CPFEM) is used to study factors affecting bond strength in polycrystals mimicking diffusion bonded microstructures. Additionally, the phase field method is also employed to simulate the grain growth and recrystallization at the bond line to model the bonding process and CPFEM is used to predict the resulting material performance to connect processing parameters to the expected creep life and ductility of the material, and to study potential means to improve the structural reliability of the material and the resulting components by optimizing the material processing parameters.
Creep Strength and Microstructure in Welded Joints of ASME Grade 91 Type 1 and Type 2 Steels
Authors: Mitsuhara Masatoshi , Sato Katsuhiro , Nomura Kyohei , Kimura Takahiro , Shioda Yoshiki , Sawada Kota , Kimura Kazuhiro , Nakashima Hideharu
Published: October 2024

In this study, the creep strength of welded joints of Grade 91 Type 1 and Type 2 steels was evaluated. It was determined that impurity elements in the Type 1 steel reduced its creep strength. This reduction was attributed to an increase in the amount of residual carbides in the fine-grain heat-affected zone during welding.
LCF and TMF of Superalloys Used for IGT Blades and Vanes
Authors: Neu Richard W. , Acharya Rohan , Caputo Alexander N. , Bridges Alex , Shingledecker John
Published: October 2024

Ni-base superalloys used for hot section hardware of gas turbine systems experience thermomechanical fatigue (TMF), creep, and environmental degradation. The blades and vanes of industrial gas turbines (IGTs) are made from superalloys that are either directionally-solidified (DS) or cast as single crystals (SX). Consequently, designing and evaluating these alloys is complex since life depends on the crystallographic orientation in addition to the complexities related to the thermomechanical cycling and the extent of hold times at elevated temperature. Comparisons between the more complex TMF tests and simpler isothermal low cycle fatigue (LCF) tests with hold times as cyclic test methods for qualifying alternative repair, rejuvenation, and heat-treatment procedures are discussed. Using the extensive set of DS and SX data gathered from the open literature, a probabilistic physics-guided neural network is developed and trained to estimate life considering the influence of crystallographic orientation, temperature, and several other cycling and loading parameters.
CEN WS064: Code Evolution and Pre-Normative Research for Generation IV Nuclear Reactor Design and Construction Codes
Authors: Nilsson Karl-Fredrik , Pétesch Cécile
Published: October 2024

This paper presents the CEN WS064 Prospective Group 2, a project involving different European stakeholders from more than 20 organizations with the objective to identify the needs and propose code developments research for the nuclear design and construction code RCC-MRx for innovative reactors with more onerous operational conditions: i) reactor components are generally exposed to higher temperatures; ii) have innovative and more corrosive coolants such as liquid lead or molten salt; iii) materials and components are generally exposed to higher radiation levels than light-water reactors. The main outputs of the CEN WS064 are code evolution proposals and proposals for pre-normative research in support of code evolution. The code evolution is driven by further improving safety and cost reduction. Nuclear Design Codes are robust engineering tools but should incorporate new technologies and research. The paper describes the adopted methodology and the rationale for identifying code evolution needs. Code evolution and research proposals will be discussed. Examples of proposals that will be discussed include: Guideline for design of material/components with innovative coolants, extension of design life to 60 years; qualification of new materials and components with advanced manufacturing. A general requirement is that code evolution and associated material and component qualification and codification need to be significantly accelerated for which new approaches such as AI tools will play an important role.
The Small Punch Creep Test: A Tool to Rank and Qualify Creep Properties for the Comparison of Forged and Additive Manufactured 316L Stainless Steels
Authors: Nilsson Karl-Fredrik , Simonovski Igor , Baraldi Daniele , Holmström Stefan
Published: October 2024

There is an increased interest in miniature testing to determine material properties. The small punch test is one miniaturized test method that has received much interest and is now being applied to support the design and life assessment of components. This paper presents the results of a test program for a small punch creep test at 650°C of 316L stainless steel produced from additive manufacturing. A major finding is that the deflection rate curve versus time may have multiple minima as opposed to forged 316L with only one minimum. This is believed to be due to microcracking and has direct consequences on the determination of the creep properties that that are based on a single minimum value in the CEN Small Punch Standard. In the paper, aged and nonaged materials are compared, and small punch creep results are also compared with standard uniaxial creep tests. The multiple minima feature means that the approach to determine equivalent stress and strain rate from the minimum deflection rate needs to be modified. Some approaches for this are discussed in the paper. Under the assumption that the multiple minima represent cracking, it opens up opportunities to quantify reduced creep ductility by the small punch test.
Effect of Ni Content on Hydrogen Embrittlement of Conventional Ni-Based Alloys
Authors: Oki Yutaro , Ando Tomohiro , Koyanagi Yoshihiko , Kitaguchi Hiroto , Chiu Yu-Lung
Published: October 2024

Hydrogen as a clean fuel is increasingly being used to propel gas turbines and to power combustion engines. Metallic materials including Ni-based alloys are commonly used in conventional gas turbines and combustion engines. However, hydrogen may cause embrittlement in these materials, depending on their chemical composition. In this work, the hydrogen embrittlement behavior of Ni-based alloys containing up to 50 wt.% Fe has been investigated using slow strain rate tensile testing, under cathodic hydrogen charging at room temperature. It was found that the larger the Ni equivalent concentration in an alloy, the more severe the hydrogen embrittlement. It was also found that solid solution alloys have less severe hydrogen embrittlement than precipitation alloys of the same Ni equivalent concentration. In solid solution alloys, hydrogen embrittlement led to cleavage type fracture, which is in line with literature where hydrogen enhanced planar deformation. In precipitation alloys, hydrogen embrittlement resulted in a typical intergranular fracture mode.
Creep Ductility in 9Cr Creep Strength Enhanced Ferritic Steels - Part I, Structural Response
Authors: Perrin Ian J. , Siefert John A. , Parker Jonathan D.
Published: October 2024

The time-dependent behavior of 9Cr creep strength enhanced ferritic (CSEF) steels has long fixated on the creep life recorded in uniaxial constant load creep tests. This focus is a consequence of the need to develop stress allowable values for use in the design by formulae approach of rules for new construction. The use of simple Design by Formula rules is justified in part by the assumption that the alloys used will invariably demonstrate high creep ductility. There appears to be little awareness regarding the implication(s) that creep ductility has on structural performance when mechanical or metallurgical notches (e.g., welds) are present in the component design or fabricated component. This reduced awareness regarding the role of ductility is largely because low alloy CrMo steels used for very many years typically were creep ductile. This paper focuses on the structural response from selected tests that have been commissioned or executed by EPRI over the last decade. The results of these tests demonstrate unambiguously the importance that creep ductility has on long-term, time-dependent behavior. The metallurgical findings from the selected tests are the focus of the Part II paper. The association of performance with notch geometry, weld strength, and other potential contributing factors will be highlighted with a primary objective of informing the reader of the variability, and heat-specific behavior that is observed among this class of alloys widely used in modern thermal fleet components and systems.
Assessing the Impact of Molten Halide Salts on Creep of Structural Alloys at 650°-750°C
Authors: Pillai Rishi , Pint Bruce A.
Published: October 2024

There is a critical lack of data on the mechanical behavior of candidate structural materials for advanced nuclear reactors under molten halide salt environments. Limited legacy data from the molten salt reactor experiment (MSRE) program showed a significant reduction in creep rupture strength of a Ni-base alloy in molten fluoride salt. With ongoing efforts to commercialize different molten salt reactor concepts, the industry can considerably benefit from quantitative information on the impact of molten halide salts on the engineering properties such as creep and fatigue strength of materials of interest. The present work aims to assess the role of molten salt corrosion on the creep behavior of three alloys 316H, 617 and 282 at 650-816 °C. Creep tests were conducted in fluoride (FLiNaK) and chloride (NaCl-MgCl2) salts. Initial results from the ongoing testing will be presented which suggest that the molten salt environment caused a 25-50% reduction in creep rupture lifetime compared to air exposures. Physics-based corrosion and creep models were employed to gain some insights into the potential degradation mechanisms.
An Investigation of J513 Alloy Powder for a Plasma-Transferred Arc Cladding Application
Authors: Qiao C. Paul
Published: October 2024

This study explores the expanded applications of Alloy J513, a high-performance material traditionally used in cast engine valvetrain components, for powder metallurgy and surface cladding applications. While already recognized for its superior heat and wear resistance at a lower cost compared to cobalt-based hardfacing materials, J513 demonstrates additional advantages in powder metallurgy applications due to its ability to achieve desired powder characteristics through atomization without requiring post-atomization annealing. Through experimental investigation based on fundamental metallurgical principles and cladding engineering processes, the presented research demonstrates J513’s exceptional weldability and favorable weldment structure compared to conventional cobalt-based alloys. The study establishes crucial relationships between weldment behavior and unit energy input, providing valuable insights for advanced cladding techniques while highlighting J513’s potential as a sustainable alternative to traditional nickel- and cobalt-based alloys in various manufacturing processes, including surface overlay and additive manufacturing.
Effect of Reheated CGHAZ Microstructure on Hydrogen-Induced Cracking Susceptibility in SA-508 Steel
Authors: Romero Fernando , Siefert William , McCracken Steven L. , Alexandrov Boian
Published: October 2024

According to ASME Case N-888-3, Similar and Dissimilar Metal Welding Using Ambient Temperature SMAW or Machine GTAW Temper Bead Technique, a 48 hr waiting period before conducting the final nondestructive examination (NDE) is required when ferritic filler weld metal is used. The purpose of the 48 hr hold is to confirm the absence of hydrogen-induced cracking in the temper bead heat-affected zone. In previous research, the effect of post-weld heat treatment (PWHT) and temper bead welding (TBW) on the hydrogen-induced cracking (HIC) susceptibility in the coarse-grained heat-affected zone (CGHAZ) in welds of SA-508, P-No. 3 Group 3, pressure vessel steel was investigated using the Delayed Hydrogen Cracking Test (DHCT). In that previous study, the Gleeble thermomechanical simulator was used to generate six CGHAZ microstructural conditions: as-welded (AW), PWHT, and AW with single a TBW reheat at 675, 700, 725, and 735°C. Hydrogen was introduced to the specimen through cathodic charging under in situ constant tensile stress. The HIC susceptibility for these microstructures was ranked by the DHCT at a diffusible hydrogen level significantly exceeding typical GTAW and SMAW processes. The work described in this paper investigates the susceptibility to HIC of these same CGHAZ microstructures with DHCT at variable current densities, further ranking each condition. Test results were analyzed by fracture surface examination of failed tests, and cross-section microstructural analysis under a scanning electron microscope (SEM). Future steps include evaluating critical hydrogen content levels using gas chromatography for each condition. The results from this study will be used to consider potential elimination of the NDE hold time requirement in Case N-888-3 when ferritic weld metal is used.
Nondestructive Detection of Creep Damage in ASME Grade 91 Steel Welds
Authors: Sawada Kota , Taniuchi Yasushi , Nojima Takehiro , Kimura Kazuhiro , Kimura Takahiro , Nomura Kyohei , Saito Noriko , Morita Akira , Hayakawa Hiroyuki , Sugiuchi Takao , Ohbitsu Kazushige , Yaguchi Masatsugu , Nishizawa Koju , Ozaki Hiroshi , Fukunishi Hayato , Ohi Kouji , Nishioka Tomoya , Emi Naoya , Okada Hirokazu , Komai Nobuyoshi , Hayashi Kyohei , Tominaga Kimihiko
Published: October 2024

This study evaluates various nondestructive testing methods for detecting creep damage and assessing residual life in Grade 91 steel welds. Three primary detection techniques were investigated: phased array ultrasonic testing (PAUT), eddy current testing with high-temperature superconductor direct current and superconducting quantum interference device (ECT•HTS-dc-SQUID), and replica observation. PAUT detected creep damage between 60-80% of creep life, while ECT•HTS-dc-SQUID showed detection capability between 80-90% of creep life. Replica observation revealed creep voids only in the final stages before rupture. Additionally, three strain measurement methods were evaluated: capacitive strain sensors (providing continuous monitoring during creep exposure), laser displacement meters (used during test interruptions), and SPICA strain measurement. Both capacitive sensors and laser meters produced results comparable to conventional extensometer measurements. The SPICA method proved particularly effective in measuring heat-affected zone (HAZ) strain after creep exposure, revealing higher strain values in the HAZ compared to base and weld metal, with a consistent increase during creep exposure.
Assessment of 316H Stainless Steel Produced by Directed Energy Deposition Additive Manufacturing for High Temperature Power Plant Applications
Authors: Sutton Ben , Jang Eun , Tate Stephen , Shingledecker John
Published: October 2024

This study evaluates the elevated temperature mechanical performance of 316H stainless steel produced using directed energy deposition (DED) additive manufacturing (AM) from three separate collaborative research programs focused on understanding how AM variables affect creep performance. By combining these studies, a critical assessment of variables was possible including the DED AM method (laser powder and gas metal arc wire), laser power, sample orientation relative to build orientation, chemical composition, and post-processing heat treatment. Detailed microstructure characterization was used to supplement creep and chemistry results to provide insights into potential mechanistic differences in behavior. The study found that sample orientation was a critical variable in determining lower-bound creep behavior, but that in general the lowest creep strength orientation and the lowest creep ductility orientation were not the same. Heat treatment was also an important variable with as-printed materials showing for specific test conditions improved performance and that underlying substructures formed due to inhomogeneous chemical distributions were not completely removed when using standard wrought solution annealing heat-treatments. The chemistry of the final deposited parts differed from the starting stock and may be an important consideration for long-term performance which is not fully appreciated. Overall, the study found that while all the DED materials tested fell within an expected wrought scatter band of performance, the actual creep performance could vary by an order of magnitude due to the many factors described.
Materials Technology for Innovative Thermal Power Generation System Toward Carbon Neutrality in Japan
Authors: Takeyama Masao
Published: October 2024

For future carbon neutral society, a novel thermal power generation system with no CO2 emission and with extremely high thermal efficiency (~ 70 %) composed of the oxygen/hydrogen combustion gas turbine combined with steam turbine with the steam temperature of 700°C is needed. The key to realize the thermal power plant is in the developments of new wrought alloys applicable to both gas turbine and steam turbine components under higher temperature operation conditions. In the national project of JST-Mirai program, we have constructed an innovative Integrated Materials Design System, consisting of a series of mechanical property prediction modules (MPM) and microstructure design modules (MDM). Based on the design system, novel austenitic steels strengthened by Laves phase with an allowable stress higher than 100 MPa for 105 h at 700°C was developed for the stream turbine components. In addition, for gas turbine components, novel solid-solution type Ni-Cr-W superalloys were designed and found to exhibit superior creep life longer than 105 h under 10 MPa at 1000°C. The superior long-term creep strengths of these alloys are attributed to the “grain-boundary precipitation strengthening (GBPS)” effect due to C14 Fe2Nb Laves phase and bcc α2-W phase precipitated at the grain boundaries, respectively.
Qualifying Additively Manufactured Eurofer97 Reduced Activation Steel for Fusion
Authors: Turk Andrej , Lenka Shaumik , Patil Dhairyasheel , Balachandran-Nair Shanoob , Churchman Callum , Gullane Alex , Crudden David
Published: October 2024

To operate future fusion power plants economically, the fusion community needs structural materials that can last longer and operate at higher temperatures than current materials, as well as better heat-dissipating components and a reliable supply chain for them. Additive manufacturing (AM) of existing reduced activation ferritic/martensitic steels (RAFMS) has the potential to solve these problems, which is why we developed a laser powder bed fusion (LPBF) process for Eurofer97 steel, demonstrating excellent mechanical properties (~30% improved yield strength, ~6300% improved creep rupture life, similar toughness and ductility compared to wrought Eurofer97) and low process scatter (relative standard error for yield, tensile strength and elongation on build plate <1%). The main remaining challenge is the consistent sourcing of quality Eurofer97 powder, but we have shown that this can already be done if the limits on impurity elements are slightly relaxed. Our work lays the groundwork for the manufacture of complex fusion components that can dissipate heat better and have a higher operating temperature thanks to the improved material properties. It also helps plug the current RAFMS supply chain gap, enabling easier component prototyping and small-scale manufacture that can smoothly scale in volume in the future.