Donna Guillen

The nuclear power industry has growing interest in qualifying powder metallurgy with hot isostatic pressing (PM-HIP) to replace traditional alloy fabrication methods for reactor structural components. But there is little known about the response of PM-HIP alloys to reactor conditions. This study directly compares the response of PM-HIP to forged Ni-base Alloy 625 under neutron irradiation doses ∼0.5–1 displacements per atom (dpa) at temperatures ranging ∼321–385 °C. Post-irradiation examination involves microstructure characterization, ASTM E8 uniaxial tensile testing, and fractography. Up through 1 dpa, PM-HIP Alloy 625 appears more resistant to irradiation-induced cavity nucleation than its forged counterpart, and consequently experiences significantly less hardening. This observed difference in performance can be explained by the higher initial dislocation density of the forged material, which represents an interstitial-biased sink that leaves a vacancy supersaturation to nucleate cavities. These findings show promise for qualification of PM-HIP Alloy 625 for nuclear applications, although higher dose studies are needed to assess the steady-state irradiated microstructure.

A new metal matrix composite material has been developed to serve as a thermal neutron absorber for testing fast reactor fuels and materials in an existing pressurized water reactor. The performance of this material was evaluated by placing neutron fluence monitors within shrouded and unshrouded holders and irradiating for up to four cycles. The monitor wires were analyzed by gamma and X-ray spectrometry to determine the activities of the activation products. Adjusted neutron fluences were calculated and grouped into three bins—thermal, epithermal, and fast—to evaluate the spectral shift created by the new material. A comparison of shrouded and unshrouded fluence monitors shows a thermal fluence decrease of *11% for the shielded monitors. Radioisotope activity and mass for each of the major activation products is given to provide insight into the evolution of thermal absorption cross section during irradiation. The thermal neutron absorption capability of the composite material appears to diminish at total neutron fluence levels of*8 9 1025 n/m2. Calculated values for dpa in excess of 2.0 were obtained for two common structural materials (iron and nickel) of interest for future fast flux experiments.

A metal matrix composite (MMC) material composed of hafnium aluminide (Al3Hf) intermetallic particles in an aluminum matrix has been identified as a promising material for fast flux irradiation testing applications. This material can filter thermal neutrons while simultaneously providing high rates of conductive cooling for experiment capsules. The purpose of this work is to investigate effects of Hf-Al material composition and neutron irradiation on thermophysical properties, which were measured before and after irradiation. When performing differential scanning calorimetry (DSC) on the irradiated specimens, a large exotherm corresponding to material annealment was observed. Therefore, a test procedure was developed to perform DSC and laser flash analysis (LFA) to obtain the specific heat and thermal diffusivity of pre- and post-annealment specimens. This paper presents the thermal properties for three states of the MMC material: (1) unirradiated, (2) as-irradiated, and (3) irradiated and annealed. Microstructure-property relationships were obtained for the thermal conductivity. These relationships are useful for designing components from this material to operate in irradiation environments. The ability of this material to effectively conduct heat as a function of temperature, volume fraction Al3Hf, radiation damage, and annealing is assessed using the MOOSE suite of computational tools.

This article presents the comprehensive mechanical testing data archive from a neutron irradiation campaign of nuclear structural alloys fabricated by powder metallurgy with hot isostatic pressing (PM-HIP). The irradiation campaign was designed to facilitate a direct comparison of PM-HIP to conventional casting or forging. Five common nuclear structural alloys were included in the campaign: 316L stainless steel, SA508 pressure vessel steel, Grade 91 ferritic steel, and Ni-base alloys 625 and 690. Irradiations were carried out in the Advanced Test Reactor (ATR) at Idaho National Laboratory (INL) to target doses of 1 and 3 displacements per atom (dpa) at target temperatures of 300 and 400 °C. This article contains the data collected from post-irradiation uniaxial tensile tests following ASTM E8 specifications, fractography of these tensile bars, and nanoindentation. By making this systematic and valuable neutron irradiated mechanical behavior dataset openly available to the nuclear materials research community, researchers may now use this data to populate material performance databases, validate material performance and hardening models, design follow-on experiments, and enable future nuclear code-qualification of PM-HIP techniques.

thermal neutron absorber material composed of Al3Hf particles in an aluminum matrix is under development for the Advanced Test Reactor. This metal matrix composite was fabricated via hot pressing of high-purity aluminum and micrometer-size Al3Hf powders at volume fractions of 20.0, 28.4, and 36.5%. Room temperature tensile and hardness testing of unirradiated specimens revealed a linear relationship between volume fraction and strength, while the tensile data showed a strong decrease in elongation between the 20 and 36.5% volume fraction materials. Tensile tests conducted at 200 °C on unirradiated material revealed similar trends. Evaluations were then conducted on specimens irradiated at 66 to 75 °C to four dose levels ranging from approximately 1 to 4 dpa. Tensile properties exhibited the typical increase in strength and decrease in ductility with dose that are common for metallic materials irradiated at ≤0.4Tm. Hardness also increased with neutron dose. The difference in strength between the three different volume fraction materials was roughly constant as the dose increased. Nanoindentation measurements of Al3Hf particles in the 28.4 vol% material showed the expected trend of increased hardness with irradiation dose. Transmission electron microscopy revealed oxygen at the interface between the Al3Hf particles and aluminum matrix in the irradiated material. Scanning electron microscopy of the exterior surface of tensile tested specimens revealed that deformation of the material occurs via plastic deformation of the Al matrix, cracking of the Al3Hf particles, and to a lesser extent, tearing of the matrix away from the particles. The fracture surface of an irradiated 28.4 vol% specimen showed failure by brittle fracture in the particles and ductile tearing of the aluminum matrix with no loss of cohesion between the particles and matrix. The coefficient of thermal expansion decreased upon irradiation, with a maximum change of −6.3% for the annealed irradiated 36.5 vol% specimen.