Search Results (81)

The microstructure evolution and hardness variations of as-fabricated and recrystallized 12Cr oxide dispersion strengthened (ODS) steel after dual-ion (6.4 MeV Fe³⁺ and energy-degraded 1 MeV He⁺) irradiation at 973 K up to 10.6 displacements per atom (dpa) at peak damage and 8900 appm He are investigated. Results show that the oxide particles slightly shrink in the as-fabricated specimen, while they are stable in the recrystallized specimen. Furthermore, larger helium bubbles are trapped at the grain boundaries in the as-fabricated specimen, and the size of helium bubbles in the grains is almost the same for both as-fabricated and recrystallized specimens, indicating that reduction of grain boundaries would reduce the potential nucleation sites and suppress the helium segregation. Moreover, no obvious hardening occurs in the as-fabricated specimen, whereas the hardness increases a little in the recrystallized specimen. Based on the barrier model, the barrier strength factor of helium bubbles is calculated. The value is 0.077, which is much smaller and suggests that helium bubbles seem not to significantly induce irradiation hardening. Full article

This study systematically investigated the effects of selective laser melting (SLM) process parameters on the forming quality and microstructure of FeCrAl oxide dispersion-strengthened (ODS) alloy. Through orthogonal experimental design, the influences of laser power (300–320 W), scanning speed (650–850 mm/s), and hatch spacing (0.05–0.07 mm) on the surface morphology and internal defects of as-built samples were analyzed. The microstructural evolution under different volumetric energy densities (VED) was also analyzed. The results indicate that hatch spacing significantly affected crack and pore formation, with minimal defects observed at 0.06 mm. Excessive laser power (320 W) or VED (318.0 J/mm³) led to elevated melt pool temperatures, causing element evaporation, grain coarsening, and <100> preferential oriented texture, thereby reducing hardness to 234 HV. The optimal parameters—laser power of 310 W, scanning speed of 650 mm/s, and hatch spacing of 0.06 mm (VED 265.0 J/mm³)—yielded the highest hardness (293 HV), fine-grained structures, and a high proportion of low-angle grain boundaries (LAGBs) with significant residual stress. This research provides a theoretical foundation for optimizing SLM processes for FeCrAl-ODS alloys. Full article

Oxide dispersion-strengthened (ODS) steels are emerging as leading candidate materials for next-generation nuclear reactor components due to their exceptional resistance to creep, fatigue, and irradiation, combined with high strength at elevated temperatures. This paper investigates the microstructural mechanisms underpinning these superior properties, with a particular focus on the critical role of nano-oxides in enhancing performance. Various manufacturing techniques, including powder metallurgy and additive manufacturing, are reviewed to assess their impact on the structural and mechanical properties of ODS steels. Recent case studies on their application in nuclear environments highlight the potential of ODS steels to significantly extend component longevity without necessitating major reactor redesigns. Nevertheless, further research is necessary to assess their reliability under extreme environmental conditions and to determine optimal, scalable manufacturing processes for large-scale production. Full article

Oxide dispersion-strengthened (ODS) steels are among the most promising candidate structural materials for fusion and Generation-IV (Gen-IV) fission reactors, but the ductility of ODS steels is inferior to its strength properties. Therefore, we investigate void nucleation, considered as the first step of ductile damage in metal, using molecular dynamics simulations. Given that the materials are subjected to extremely complex stress states within the reactor, we present the void nucleation process of 1–4 nm Y₂O₃ nanoclusters in bcc iron during uniaxial, biaxial, and triaxial tensile deformation. We find that the void nucleation process is divided into two stages depending on whether the dislocations are emitted. Void nucleation occurs at smaller strain in biaxial and triaxial tensile deformation in comparation to uniaxial tensile deformation. Increasing the size of clusters results in a smaller strain for void nucleation. The influence of 1 nm clusters on the process of void nucleation is slight, and the void nucleation process of 1 nm cluster cases is similar to that of pure iron. In addition, void nucleation is affected by both stress and strain concentration around the clusters, and the voids grow first in the areas of high stress triaxiality. Full article

Oxide dispersion-strengthened (ODS) alloys demonstrate enhanced mechanical properties at elevated temperatures and show potential as next-generation powder materials for additive manufacturing. These alloys can mitigate defects such as micropores and cracks by regulating solidification and grain growth behaviors during the additive manufacturing process. This study investigates the fabrication technology for ODS Ti-6Al-2Sn-4Zr-2Mo (Ti6242) alloy powder to achieve uniform oxide distribution within the alloy powders. Thermodynamic calculations were employed to determine the optimal Ti6242–Y₂O₃ composition for in situ gas atomization, ensuring complete dissolution of the oxide in the Ti6242 molten metal and subsequent reprecipitation upon cooling. A rod-shaped ingot was produced via vacuum arc melting, resulting in coarse Y₂O₃ precipitating along the grain boundaries. The powder was fabricated through an electrode induction gas atomization method, and the ODS Ti6242 powder exhibited a spherical shape and a smooth surface. Cross-sectional analysis revealed the uniform distribution of Y₂O₃ oxide particles, measuring several tens of nanometers in size, within the alloy powder. This research demonstrates the successful synthesis of oxide-integrated ODS Ti6242 alloy powder through the in situ gas atomization method, potentially advancing the field of additive manufacturing for high-temperature applications. Full article

Laser Powder Bed Fusion (LPBF) enables the efficient production of near-net-shape oxide dispersion-strengthened (ODS) alloys, which possess superior mechanical properties due to oxide nanoparticles (e.g., yttrium oxide, Y-O, and yttrium-titanium oxide, Y-Ti-O) embedded in the alloy matrix. To better understand the precipitation mechanisms of the oxide nanoparticles and predict their size distribution under LPBF conditions, we developed an innovative physics-based multiscale modeling strategy that incorporates multiple computational approaches. These include a finite volume method model (Flow3D) to analyze the temperature field and cooling rate of the melt pool during the LPBF process, a density functional theory model to calculate the binding energy of Y-O particles and the temperature-dependent diffusivities of Y and O in molten 316L stainless steel (SS), and a cluster dynamics model to evaluate the kinetic evolution and size distribution of Y-O nanoparticles in as-fabricated 316L SS ODS alloys. The model-predicted particle sizes exhibit good agreement with experimental measurements across various LPBF process parameters, i.e., laser power (110–220 W) and scanning speed (150–900 mm/s), demonstrating the reliability and predictive power of the modeling approach. The multiscale approach can be used to guide the future design of experimental process parameters to control oxide nanoparticle characteristics in LPBF-manufactured ODS alloys. Additionally, our approach introduces a novel strategy for understanding and modeling the thermodynamics and kinetics of precipitation in high-temperature systems, particularly molten alloys. Full article

A significant effort in optimizing the chemical composition and powder metallurgical processing led to preparing new-generation ferritic coarse-grained ODS alloys with a high nano-oxide content. The optimization was aimed at high-temperature creep and oxidation resistance at temperatures in the range of 1100–1300 °C. An FeAlOY alloy, with the chemical composition Fe–10Al–4Cr–4Y₂O₃ (wt. %), seems as the most promising one. The consolidation of the alloy is preferably conducted by hot rolling in several steps, followed by static recrystallization for 1 h at 1200 °C, which provides a stable coarse-grain microstructure with homogeneous dispersion of nano-oxides. This represents the most cost-effective way of production. Another method of consolidation tested was hot rotary swaging, which also gave promising results. The compression creep testing of the alloy at 1100, 1200, and 1300 °C shows excellent creep performance, which is confirmed by the tensile creep tests at 1100 °C as well. The potential in such a temperature range is the target for possible applications of the FeAlOY for the pull rods of high-temperature testing machines, gas turbine blades, or furnace fan vanes. The key effort now focuses on expanding the production from laboratory samples to larger industrial pieces. Full article

Oxide-dispersion-strengthened (ODS) alloys generally exhibit extraordinary service performance under severe conditions through the formation of ultrafine nano oxides. Y₂Ti₂O₇ has been characterized as the major strengthening oxide in Fe-based ODS alloys. First-principles energetic analyses were performed to investigate the structural, elastic and interface properties of Y₂Ti₂O₇ in either Fe-based or Ni-based ODS alloys. Y₂Ti₂O₇ has comparable elastic constants to bcc-Fe and fcc-Ni and similar elastic deformation compatibility in Y₂Ti₂O₇-strengthened Fe-based and Ni-based ODS alloys is therefore expected. The Ni/oxide interface has generally better thermostability than Fe/oxide across the whole range of the concerned oxygen chemical potential. Further interface bonding and adhesion calculations revealed that Y₂Ti₂O₇ can enhance the bonding strength of Ni/Y₂Ti₂O₇ through d-d orbital interaction between the interfacial YTi layer and Ni layer, while the interface bonding between the Fe layer and YTi layer is weakened compared to the metal matrix. First-principles calculations suggest that Y₂Ti₂O₇ can be a candidate for strengthening nano-oxides in either Fe-based or Ni-based ODS alloys with well-behaved mechanical properties for fourth-generation fission reactors and further experimental validations are encouraged. Full article

Nanostructured ferritic alloys (NFAs), such as oxide-dispersion strengthened (ODS) alloys, play a vital role in advanced fission and fusion reactors, offering superior properties when incorporating nanoparticles under irradiation. Despite their importance, the high cost of mass-producing NFAs through mechanical milling presents a challenge. This study delves into the microstructure-mechanical property correlations of three NFAs produced using a novel, cost-effective approach combining severe plastic deformation (SPD) with the continuous thermomechanical processing (CTMP) method. Analysis using scanning electron microscopy (SEM)-electron backscatter diffraction (EBSD) revealed nano-grain structures and phases, while scanning transmission electron microscopy (STEM)-energy dispersive X-ray spectroscopy (EDS) quantified the size and density of Ti-N, Y-O, and Cr-O fine particles. Atom probe tomography (APT) further confirmed the absence of finer Y-O particles and characterized the chemical composition of the particles, suggesting possible nitride dispersion strengthening. Correlation of microstructure and mechanical testing results revealed that CTMP alloys, despite having lower nanoparticle densities, exhibit strength and ductility comparable to mechanically milled ODS alloys, likely due to their fine grain structure. However, higher nanoparticle densities may be necessary to prevent cavity swelling under high-temperature irradiation and helium gas production. Further enhancements in uniform nanoparticle distribution and increased sink strength are recommended to mitigate cavity swelling, advancing their suitability for nuclear applications. Full article

This paper presents corrosion resistance results of a 12Cr ferritic ODS steel (Fe-12Cr-2W-0.5Zr-0.3Y₂O₃) fabricated via a powder metallurgy route as a prospective applicant for fuel cladding materials. In a spent nuclear fuel reprocessing facility, nitric acid serves as the primary solvent in the PUREX method. Therefore, fundamental immersion and electrochemical tests were conducted in various nitric acid solutions to evaluate corrosion degradation behavior. Additionally, polarization tests were also performed in 0.61 M of sodium chloride solutions (seawater-like atmosphere) as a more general, all-purpose procedure that produces valid comparisons for most metal alloys. For comparison, martensitic X46Cr13 steel was also examined under the same conditions. In general, the corrosion resistance of the 12Cr ODS steel was better than its martensitic counterpart despite a lower nominal chromium content. Potentiodynamic polarization plots exhibited a lower corrosion current and higher breakdown potentials in chloride solution in the case of the ODS steel. It was found that the corrosion rate during immersion tests was exceptionally high in diluted (0.1–3 M) boiling nitric acid media, followed by its sharp decrease in more concentrated solutions (>4 M). The results of the polarization plots also exhibited a shift toward more noble corrosion potential as the concentrations increased from 1 M to 4 M of HNO₃. The results on corrosion resistance were supported by LSCM and SEM observations of surface topology and corrosion products. Full article

High-performance structural materials (HPSMs) are needed for the successful and safe design of fission and fusion reactors. Their operation is associated with unprecedented fluxes of high-energy neutrons and thermomechanical loadings. In fission reactors, HPSMs are used, e.g., for fuel claddings, core internal structural components and reactor pressure vessels. Even stronger requirements are expected for fourth-generation supercritical water fission reactors, with a particular focus on the HPSM’s corrosion resistance. The first wall and blanket structural materials in fusion reactors are subjected not only to high energy neutron irradiation, but also to strong mechanical, heat and electromagnetic loadings. This paper presents a historical and state-of-the-art summary focused on the properties and application potential of irradiation-resistant alloys predominantly strengthened by an oxide dispersion. These alloys are categorized according to their matrix as ferritic, ferritic–martensitic and austenitic. Low void swelling, high-temperature He embrittlement, thermal and irradiation hardening and creep are typical phenomena most usually studied in ferritic and ferritic martensitic oxide dispersion strengthened (ODS) alloys. In contrast, austenitic ODS alloys exhibit an increased corrosion and oxidation resistance and a higher creep resistance at elevated temperatures. This is why the advantages and drawbacks of each matrix-type ODS are discussed in this paper. Full article

Lead-cooled fast reactors exhibit strong inherent safety performance and good economic features, while material degradation due to corrosion and irradiation is still challenging. Oxide dispersion-strengthened steels are one of the promising candidates for fuel cladding materials. The effects of both irradiation and corrosion on ODS steel need to be further studied. In this work, MX-ODS steel was irradiated by Fe ions at 500 °C up to 46 dpa. Later, the as-received specimen and the irradiated specimen were used to conduct corrosion tests in oxygen-saturated Pb at 550 °C for 1 h. In the as-received specimen, discontinuous oxides penetrated by Pb and Pb in contact with steel matrix were observed, demonstrating unsatisfactory corrosion resistance of the material. However, in the irradiated specimen after corrosion experiment, a protective oxide layer formed and prevented Pb attack. The oxidation behavior differences between the two specimens can be attributed to the defects produced by irradiation and the structural discrepancy in oxides caused by the formation process. A possible mechanism of irradiation on the corrosion is discussed. In the as-received specimen, Fe atoms loss led to voids in the oxides, and lead penetrated the oxides through these voids. In the irradiated specimen, defects left by previous irradiation helped to form a more uniform oxide layer. The adhesive outer magnetite oxide and the Fe ions generated from where grain boundary oxidation developed retarded the presence of voids and made the oxide layer protective. Full article

Oxide Dispersion Strengthened (ODS) ferritic steels are promising materials for the nuclear power sector. This paper presents the results of a study on the sintering process using the Spark Plasma Sintering (SPS) technique, focusing on ODS ferritic steel powders with different contents (0.3 and 0.6 vol.%) of Y₂O₃. The novelty lies in the analysis of the effect of pre-annealing treatment on powders previously prepared by mechanical alloying on the microstructure, mechanical, and thermal properties of the sinters. Using the SPS method, it was possible to obtain well-densified sinters with a relative density above 98%. Pre-annealing the powders resulted in an increase in the relative density of the sinters and a slight increase in their thermal conductivity. The use of low electron energies during SEM analysis allowed for a fairly good visualization of the reinforcing oxides uniformly dispersed in the matrix. Analysis of the Mössbauer spectroscopy results revealed that pre-annealing induces local atomic rearrangements within the solid solution. In addition, there was an additional spectral component, indicating the formation of a Cr-based paramagnetic phase. The ODS material with a higher Y₂O₃ content showed increased Vickers hardness values, as well as increased Young’s modulus and nanohardness, as determined by nanoindentation tests. Full article

Oxide-dispersion-strengthened (ODS) steels have long been viewed as a prime solution for harsh environments. However, conventional manufacturing of ODS steels limits the final product geometry, is difficult to scale up to large components, and is expensive due to multiple highly involved, solid-state processing steps required. Additive manufacturing (AM) can directly incorporate dispersion elements (e.g., Y, Ti and O) during component fabrication, thus bypassing the need for an ODS steel supply chain, the scale-up challenges of powder processing routes, the buoyancy challenges associated with casting ODS steels, and the joining issues for net-shape component fabrication. In the AM process, the diffusion of the dispersion elements in the molten steel plays a key role in the precipitation of the oxide particles, thereby influencing the microstructure, thermal stability and high-temperature mechanical properties of the resulting ODS steels. In this work, the atomic diffusivities of Y, Ti, and O in molten 316L stainless steel (SS) as functions of temperature are determined by ab initio molecular dynamics simulations. The latest Vienna Ab initio Simulation Package (VASP) package that incorporates an on-the-fly machine learning force field for accelerated computation is used. At a constant temperature, the time-dependent coordinates of the target atoms in the molten 316L SS were analyzed in the form of mean square displacement in order to obtain diffusivity. The values of the diffusivity at multiple temperatures are then fitted to the Arrhenius form to determine the activation energy and the pre-exponential factor. Given the challenges in experimental measurement of atomic diffusivity at such high temperatures and correspondingly the lack of experimental data, this study provides important physical parameters for future modeling of the oxide precipitation kinetics during AM process. Full article

The microstructure evolution associated with the cold forming sequence of an Fe-14Cr-1W-0.3Ti-0.3Y₂O₃ grade ferritic stainless steel strengthened by dispersion of nano oxides (ODS) was investigated. The material, initially hot extruded at 1100 °C and then shaped into cladding tube geometry via HPTR cold pilgering, shows a high microstructure stability that affects stress release heat treatment efficiency. Each step of the process was analyzed to better understand the microstructure stability of the material. Despite high levels of stored energy, heat treatments, up to 1350 °C, do not allow for recrystallization of the material. The Vickers hardness shows significant variations along the manufacturing steps. Thanks to a combination of EBSD and X-ray diffraction measurements, this study gives a new insight into the contribution of statistically stored dislocation (SSD) recovery on the hardness evolution during an ODS steel cold forming sequence. SSD density, close to 4.10¹⁵ m⁻² after cold rolling, drops by only an order of magnitude during heat treatment, while geometrically necessary dislocation (GND) density, close to 1.10¹⁵ m⁻², remains stable. Hardness decrease during heat treatments appears to be controlled only by the evolution of SSD. Full article