Metals and alloys fabricated by fusion-based additive manufacturing (AM), or 3D printing, undergo complex dynamics of melting and solidification, presenting challenges to the effective control of grain structure. Herein, we report on the use of high-intensity ultrasound that controls the process of solidification during AM of 316L stainless steel. We find that the use of ultrasound favours the columnar-to-equiaxed transition, promoting the formation of fine equiaxed grains with random crystallographic texture. Moreover, the use of ultrasound increases the number density of grains from 305 mm-2 to 2748 mm-2 despite an associated decrease in cooling rate and temperature gradient in the melt pool during AM. Our assessment of the relationship between grain size and cooling rate indicates that the formation of crystallites during AM is enhanced by ultrasound. Furthermore, the use of ultrasound increases the amount of constitutional supercooling during solidification by lowering the temperature gradient in the bulk of the melt pool, thus creating an environment that favours nucleation, growth, and survival of grains. This new understanding provides opportunities to better exploit ultrasound to control grain structure in AM-fabricated metal products.
A three-dimensional model of a partially melted powder bed with particles stochastically distributed in size and space coordinates has been developed. Numerical simulation of temperature distributions in stainless steel AISI 316L and Al-12Si powders in vacuum, air and argon has been performed to analyze unsteady heat transfer in a porous medium. The numerical model demonstrates a large effect of heat transfer through the gas phase in case of powders with low thermal conductivities like stainless steels. At the porosity level of 65\% and above, the mechanism of heat transfer drastically changes…
This work addresses the early stages ($\le$1000 h) of the dissolution corrosion behavior of 316L and DIN 1.4970 austenitic stainless steels in contact with oxygen-poor (C$_O$ < 10$^-$$^8$ mass%), static liquid lead-bismuth eutectic (LBE) at 500°C for 600-1000 h. The objective of this study was to determine the relative early-stage resistance of the uncoated steels to dissolution corrosion and to assess the protectiveness of select candidate coatings (Cr$_2$AlC, Al$_2$O$_3$, V$_2$Al$_x$C$_y$). The simultaneous exposure of steels with intended differences in microstructure and thermomechanical s…
Laser Shock Peening (LSP) of stainless-steel 316 and 316L was studied using Ti: Sapphire laser pulses of about 2 ps duration, maximum energy of about 1mJ and pulse repetition rate of 5kHz in different liquid confinement media of Ethanol, Deionized water and separate aqueous solutions of NaCl and Glycerol. It is found that the laser fluence and/or energy attenuating mechanisms like self-focusing, filamentation, plasma breakdown in the confinement media are less significant with ps laser pulses than those with sub-ps or fs pulse durations. It is shown that the resulting surface hardness of the p…
Vertically aligned carbon nanotube (CNT) forests are a particularly interesting class of nanomaterials, because they combine multifunctional properties, such as high energy absorption, compressive strength, recoverability and super-hydrophobicity with light weight. These characteristics make them suitable for application as coating, protective layers and antifouling substrates for metallic pipelines and blades. Direct growth of CNT forests on metals offers the possibility to transfer the tunable CNT functionalities directly onto the desired substrates. Here, we focus on characterizing the stru…
In order to reduce cobalt within the primary circuit of pressurised water reactors (PWRs), wear-resistant steels are being researched and developed. In particular interest is the understanding of galling mechanisms, an adhesive wear mechanism which is particularly prevalent in PWR valves. Here we show that large shear stresses and adhesive transfer occur during galling by exploiting the 2 wt per cent manganese difference between 304L and 316L stainless steels, even at relatively low compressive stresses of 50 MPa. Through these findings, the galling mechanisms of stainless steels can be better…
Effective post-heat treatment is critical to achieve desired microstructure for high-performance in additively manufactured (AM) components. In this work, the influence of homogenization on microstructure-property relationship in 17-4PH steels has been investigated. Precipitation of NbC, oxides, and ε-Cu were observed in the as-built 17-4PH steels. To design an optimum post-heat treatment, homogenization was performed at 1050oC for different times followed by aging at 482oC for 1 hour. It was identified that homogenization for 1 hour followed by aging leads to the best combination of strength …
In this paper we report on the competition in metal surface hardening between the femtosecond shock peening on the one hand, and formation of laser-induced periodic surface structures (LIPSS) and surface oxidation on the other hand. Peening of the stainless steel AISI 316 due to shock loading induced by femtosecond laser ablation was successfully demonstrated. However, for some range of processing parameters, surface erosion due to LIPSS and oxidation seem to dominate over the peening effect. Strategies to increase the peening efficiency are discussed.
The galling behaviour of 316L stainless steel was investigated in both the unoxidised and oxidised states, after exposure in simulated PWR water for 850 hours. Galling testing was performed according to ASTM G196 in ambient conditions. 316L was found to gall by the wedge growth and flow mechanism in both conditions. This resulted in folds ahead of the prow and adhesive junction, forming a heavily sheared multilayered prow. The galling trough was seen to have failed through successive shear failure during wedge flow. Immediately beneath the surface a highly sheared nanocrystalline layer was see…
Electrochemical polarization measurements were combined with surface analysis by Time of Flight Secondary Ion Mass Spectroscopy (ToF-SIMS), X-Ray Photoelectron Spectroscopy (XPS) and Atomic Force Microscopy (AFM) to study the alterations of the passive film on 316L austenitic stainless steel induced by the presence of chlorides in sulfuric acid electrolyte. The work was performed at a stage of initiation of localized corrosion preceding metastable pitting at the micrometer scale as verified by current transient analysis and AFM. The results show that Cl-ions enter the bilayer structure of the …
Time of Flight Secondary Ion Mass Spectroscopy, X-Ray Photoelectron Spectroscopy, in situ Photo-Current Spectroscopy and electrochemical analysis were combined to characterize the physicochemical alterations induced by electrochemical passivation of the surface oxide film providing corrosion resistance to 316L stainless steel. The as-prepared surface is covered by a ~2 nm thick, mixed (Cr(III)-Fe(III)) and bi-layered hydroxylated oxide. The inner layer is highly enriched in Cr(III) and the outer layer less so. Molybdenum is concentrated, mostly as Mo(VI), in the outer layer. Nickel is only pre…
A metal-oxide film can be used as a hydrogen-isotope permeation barrier in the fuel circulation system for nuclear fusion. We fabricated Er$_2$O$_3$ thin film on a type 316L stainless-steel substrate by using a metal-organic chemical vapor deposition technique for the purpose of hydrogen-isotope permeation barrier. Electron microscopy based imaging and energy-dispersive X-ray spectroscopy measurements indicate a sound film quality together with X-ray diffraction experiments. We also measured deuterium permeation in the film at high temperatures ranging from 600 $^{\circ}$C to 800 $^{\circ}$C. …
This paper is devoted to experimental characterisation of linear thermal expansion coefficient (LTEC) and mechanical characteristics of the laser deposited Cu-Fe system multilayer functionally graded (FG) structures and binary Cu-Fe alloys, fabricated from the tin, aluminium, and chromium bronze with 89-99 wt.% of copper and stainless steel (SS) AISI 316L with 1:1 and 3:1 bronze-to-steel ratio. The best tensile mechanical strength of as-built parts is demonstrated by the aluminium bronze-stainless steel 1:1 alloy and reaches 876.4 MPa along with low elasticity modulus (11.2 GPa) and 1.684 1/K …
The current work combines the Cluster Dynamics (CD) technique and CALPHAD-based precipitation modeling to address the second phase precipitation in cold-worked (CW) 316 stainless steels (SS) under irradiation at 300-400 C. CD provides the radiation enhanced diffusion and dislocation evolution as inputs for the precipitation model. The CALPHAD-based precipitation model treats the nucleation, growth and coarsening of precipitation processes based on classical nucleation theory and evolution equations, and simulates the composition, size and size distribution of precipitate phases. We benchmark t…
In the present study, superheating treatment has been applied on A357 reinforced with 0.5 wt. % (Composite 1) and 1.0 wt.% (Composite 2) continuous stainless steel composite. In Composite 1 the microstructure displayed poor bonding between matrix and reinforcement interface. Poor bonding associated with large voids also can be seen in Composite 1. The results also showed that coarser eutectic silicon (Si) particles were less intensified around the matrix-reinforcement interface. From energy dispersive spectrometry (EDS) elemental mapping, it was clearly shown that the distribution of eutectic …
The acoustic nonlinearity parameter(beta) is sensitive to dislocation parameters, which continuously change during plastic deformation. Dislocation-based damage in structures/components is the source of the failure; thus, beta has been studied as a metric for non-destructive evaluation. This work consists of two parts: the development of an in situ experimental setup for nonlinear Rayleigh wave measurements, and characterization of the dependence of beta on applied stress at different levels of initial plastic strain. First, we introduce an experimental setup and methods for repeatable in situ…
Under standard operating conditions, the emissivity of structural alloys used for various components of nuclear reactors may evolve, affecting the heat transfer of the systems. In this study, mid-infrared emissivities of several reactor structural alloys were measured before and after exposure to environments relevant to next-generation reactors. We evaluated nickel-based alloys Haynes 230 and Inconel 617 exposed to helium gas at 1000 $^{\circ}$C, nickel-based Hastelloy N and iron-based 316 stainless steel exposed to molten salts at 750-850 $^{\circ}$C, 316 stainless steel exposed to liquid so…
The microstructural evolution of a dissimilar metal weld (DMW) obtained by narrow-gap gas tungsten arc welding (NG-GTAW) was investigated after it was subjected to a post-weld heat treatment (PWHT). The case studied here is a joint between low-alloy steel pipes and a stainless steel steam generator using a nickel based alloy as filler material. The fusion boundary that was the focus of this work was that between the low-alloy steel (2.25Cr-1Mo) and the nickel alloy (alloy 82). The difference in matrix phase and chemical composition between the two alloys leads to a large difference in chemical…
In a no-insulation (NI) REBCO magnet, the turn-to-turn contact resistivity (Rc) determines its quench self-protection capability, charging delay time and the energy loss during field ramps. Therefore it is critically important to be able to control a range of Rc values suitable for various NI magnet coils. We used a commercial oxidizing agent Ebonol C to treat the copper surface of REBCO tapes. The copper oxide layer was characterized by cross-sectional transmission electron microscopy (TEM) and x-ray photoelectron spectroscopy (XPS). The oxide layer formed in Ebonol C at 98 °C for 1 min is Cu…
The mechanical and tribological properties of steel matrix composites (316L stainless steel reinforced with Cr3C2 ceramic particles) were investigated. The steel matrix composites (SMC) with three reinforcing percentages (3, 6, and 9 wt.%) were manufactured by Additive Manufacturing technologies (SLM: Selective Laser Melting). The wear behaviour was studied by using a pin-on-disk wear test at room temperature. The worn surface was analysed using Scanning Electron Microscopy (SEM). The results indicated that the friction coefficient does not have a clear tendency or direct correlation with the …
The mechanical performance of Directed Energy Deposition Additive Manufactured (DED-AM) components can be highly material dependent. Through in situ and operando synchrotron X-ray imaging we capture the underlying phenomena controlling build quality of stainless steel (SS316) and titanium alloy (Ti6242 or Ti-6Al-2Sn-4Zr-2Mo). We reveal three mechanisms influencing the build efficiency of titanium alloys compared to stainless steel: blown powder sintering; reduced melt-pool wetting due to the sinter; and pore pushing in the melt-pool. The former two directly increase lack of fusion porosity, wh…
