"Projection-capacitor discharge resistance welding of 430 stainless steel and 14YWT"
Thomas Lienert, Calvin Lear, Todd Steckley, Lindsey Lindamood, Jerry Gould, Stuart Maloy, Ben Eftink,
Journal of Manufacturing Processes
Vol. 75
2022
1189-1201
Link
Efforts to advance structural materials with improved properties and service life in support of next generation designs for nuclear reactor components have recently led to development of nano-ferritic alloys (NFAs) containing nano-oxides such as 14YWT. A key enabling technology to realizing the useful properties of NFAs during service involves preservation of the oxide dispersions during joining. Solid-state welding processes, such as projection-capacitor discharge resistance welding (P-CDRW) used here, are well suited for joining NFAs while retaining the oxides. Due to limitations in the supply of 14YWT NFA material, initial experiments were conducted using 430 stainless steel as an inexpensive surrogate material. The goal of the surrogate experiments was to scale suitable parameters from 430 welds to 14YWT using ratios of key properties for the two materials including flow stress at temperatures and strain rates relevant to hot working. Results indicated that weld displacement increased with increasing weld force and increasing weld energy for all other variables held constant. Weld energy appeared to have a larger effect on displacement than weld force for the sample geometry used here. Appropriate process parameters (no melting) were established for the two materials. The process window for the 430 material extended from 350 J to 600 J of energy for weld forces of 2.2 kN and 3.1 kN. Suitable parameters for 14YWT were similar in terms of energy but for force levels of 3.1 kN and 4.0 kN. Displacement for both materials ranged from 150 μm to 300 μm for welds that did not experience melting. Simple heat flow analysis confirmed that the extent of displacement was limited by the characteristic thermal distance determined from thermo-physical properties and the weld current rise time. The higher flow stresses of 14YWT relative to 430 were apparently offset by greater heating due to higher electrical resistivity near the projection tip and lesser heat conduction from the projection tip owing to lower thermal conductivity. Based on the results presented here and in our companion paper. The P-CDRW process appears capable of successfully joining the 14YWT NFA while retaining the microstructures and properties of the original material. |
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"Solid state welding of the nanostructured ferritic alloy 14YWT using a capacitive discharge resistance welding technique"
Calvin Lear, Jonathan Gigax , Matt Schneider, Todd Steckley, Thomas Lienert, Stuart Maloy, Ben Eftink,
Metals
Vol. 12
2021
23
Link
Joining nanostructured ferritic alloys (NFAs) has proved challenging, as the nano-oxides that provide superior strength, creep resistance, and radiation tolerance at high temperatures tend to agglomerate, redistribute, and coarsen during conventional fusion welding. In this study, capacitive discharge resistance welding (CDRW)—a solid-state variant of resistance welding—was used to join end caps and thin-walled cladding tubes of the NFA 14YWT. The resulting solid-state joints were found to be hermetically sealed and were characterized across the weld region using electron microscopy (macroscopic, microscopic, and nanometer scales) and nanoindentation. Microstructural evolution near the weld line was limited to narrow (~50–200 μm) thermo-mechanically affected zones (TMAZs) and to a reduction in pre-existing component textures. Dispersoid populations (i.e., nano-oxides and larger oxide particles) appeared unchanged by all but the highest energy and power CDRW condition, with this extreme producing only minor nano-oxide coarsening (~2 nm → ~5 nm Ø). Despite a minimal microstructural change, the TMAZs were found to be ~10% softer than the surrounding base material. These findings are considered in terms of past solid-state welding (SSW) efforts—cladding applications and NFA-like materials in particular—and in terms of strengthening mechanisms in NFAs and the potential impacts of localized temperature–strain conditions during SSW. |
"Capacitive Discharge Resistance Welding for ODS Steel Cladding: Weld Properties and Radiation Resistance" Calvin Lear, Ben Eftink, Thomas Lienert, Stuart Maloy, Todd Steckley, Materials in Nuclear Energy Systems (MiNES) October 6-10, (2019) Link | |
"Capacitive Discharge Resistance Welding of 14YWT and Other Alloys" Calvin Lear, Ben Eftink, Lindsey Lindamood, Todd Steckley, Matt Schneider, Jerry Gould, Thomas Lienert, Stuart Maloy, TMS 2020 Annual Meeting & Exhibition February 23-27, (2020) | |
"Impact of Capacitive Discharge Resistance Welding on the Radiation Tolerance of 14YWT Cladding" Calvin Lear, Hyosim Kim, Matt Schneider, Todd Steckley, Yongqiang Wang, Thomas Lienert, Stuart Maloy, Ben Eftink, Structural Materials for Innovative Nuclear Systems (SMINS-6) September 12-15, (2022) |
"Dynamic Deformation Behaviors in Single Body-Centered-Cubic (BCC) phase Refractory High-entropy Alloys"
Dongyue Xie, Juntan Li, Aomin Huang, Calvin Lear, Elham Mirkoohi, Bart Prorok, Marc Meyers, Haixuan Xu, Gian Song, Peter Liaw, George Gray, Nan Li, Saryu Fensin, Chanho Lee,
[2023]
· DOI: 10.21203/rs.3.rs-3471175/v1
The mechanical behavior and microstructural evolution of a single body-centered-cubic (BCC) phase NbTaTiV refractory high-entropy alloy (RHEA) were studied over a wide range of strain-rates (from 1 × 10-4 to 2 × 103 s-1) and temperatures [from room temperature (RT) to 850 °C]. The evolution of yield strength as a function of strain rate and temperature showed that the present RHEA had less strain-rate dependence and a strong resistance to softening at high temperatures. The formation of thin type-I twins was observed during high-strain rate deformation. The present work also showed that the thin twins did not significantly affect the work-hardening/softening rate during high strain-rate testing at all temperatures. Contrary to the high strain-rate behavior, substantial strain-hardening was observed at quasi-static rates, when the materials were tested at cryogenic temperatures. This difference in behavior was attributed to the formation of “thick” twins at cryogenic temperatures, which not only act as stronger barriers to dislocation motion but also interact with each other leading to an increase in the work hardening rate. The temperature increase during high strain-rate testing was estimated by theoretical calculations. The relatively low stacking fault energies with high twinning stress for NbTaTiV were predicted by density functional theory calculations. Moreover, a modified Zerilli-Armstrong constitutive model was also fit to represent the strength of this material at varying strain rates and temperatures. |
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"Transition in helium bubble strengthening of copper from quasi-static to dynamic deformation" M.R. Chancey, R. Flanagan, J.G. Gigax, M.T. Hoang, D.R. Jones, H. Kim, D.T. Martinez, B.M. Morrow, N. Mathew, Y. Wang, N. Li, J.R. Payton, M.B. Prime, S.J. Fensin, C.R. Lear, [2023] Acta Materialia · DOI: 10.1016/j.actamat.2023.118987 | |
"Mechanical performance and microstructure of the grade 91 stainless steel produced via Directed Energy deposition laser technique" J. Bickel, T. Mukherjee, T. DebRoy, T.J. Lienert, S.A. Maloy, C.R. Lear, P. Hosemann, S. Samuha, [2023] Materials & Design · DOI: 10.1016/j.matdes.2023.111804 | |
"The mechanical and microstructural response of single crystal aluminium to one dimensional shock loading: The effects of orientation" S.J. Fensin, G.D. Owen, B.P. Eftink, Calvin Lear, G. Whiteman, G.T. Gray, J.C.F. Millett, [2023] Acta Materialia · DOI: 10.1016/j.actamat.2023.118727 | |
"Tempering kinetics during multilayer laser additive manufacturing of a ferritic steel" T. DebRoy, T.J. Lienert, S.A. Maloy, C.R. Lear, P. Hosemann, T. Mukherjee, [2022] Journal of Manufacturing Processes · DOI: 10.1016/j.jmapro.2022.08.061 · ISSN: 1526-6125 | |
"Effects of helium cavity size and morphology on the strength of pure titanium" J.G. Gigax, O. El Atwani, M.R. Chancey, H. Kim, N. Li, Y. Wang, S.J. Fensin, C.R. Lear, [2022] Scripta Materialia · DOI: 10.1016/j.scriptamat.2022.114531 · ISSN: 1359-6462 | |
"Projection-capacitor discharge resistance welding of 430 stainless steel and 14YWT" C.R. Lear, T.E. Steckley, L.R. Lindamood, J.E. Gould, S.A. Maloy, B.P. Eftink, T.J. Lienert, [2022] Journal of Manufacturing Processes · DOI: 10.1016/j.jmapro.2022.01.036 · ISSN: 1526-6125 | |
"Solid-State Welding of the Nanostructured Ferritic Alloy 14YWT Using a Capacitive Discharge Resistance Welding Technique"
Jonathan Gregory Gigax, Matthew M. Schneider, Todd Edward Steckley, Thomas J. Lienert, Stuart Andrew Maloy, Benjamin Paul Eftink, Calvin Robert Lear,
[2021]
Metals
· DOI: 10.3390/met12010023
Joining nanostructured ferritic alloys (NFAs) has proved challenging, as the nano-oxides that provide superior strength, creep resistance, and radiation tolerance at high temperatures tend to agglomerate, redistribute, and coarsen during conventional fusion welding. In this study, capacitive discharge resistance welding (CDRW)—a solid-state variant of resistance welding—was used to join end caps and thin-walled cladding tubes of the NFA 14YWT. The resulting solid-state joints were found to be hermetically sealed and were characterized across the weld region using electron microscopy (macroscopic, microscopic, and nanometer scales) and nanoindentation. Microstructural evolution near the weld line was limited to narrow (~50–200 μm) thermo-mechanically affected zones (TMAZs) and to a reduction in pre-existing component textures. Dispersoid populations (i.e., nano-oxides and larger oxide particles) appeared unchanged by all but the highest energy and power CDRW condition, with this extreme producing only minor nano-oxide coarsening (~2 nm → ~5 nm Ø). Despite a minimal microstructural change, the TMAZs were found to be ~10% softer than the surrounding base material. These findings are considered in terms of past solid-state welding (SSW) efforts—cladding applications and NFA-like materials in particular—and in terms of strengthening mechanisms in NFAs and the potential impacts of localized temperature–strain conditions during SSW. |
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"Additive Manufacturing of structural materials for nuclear application and rapid mesoscale mechanical testing" Jason Duckering, Andrew Dong, Jeff Bickel, Stuart Maloy, Thomas Lienert, Calvin Lear, Tuhin Mukherjee, Tarasankar DebRoy, Peter Hosemann, [2021] Microscopy and Microanalysis · DOI: 10.1017/s1431927621007765 · ISSN: 1431-9276 | |
"Saver: A Peak Velocity Extraction Program for Advanced Photonic Doppler Velocimetry Analysis" D. R. Jones, M. B. Prime, S. J. Fensin, C. R. Lear, [2021] Journal of Dynamic Behavior of Materials · DOI: 10.1007/s40870-021-00295-7 · ISSN: 2199-7446 | |
"The Role of Helium on Ejecta Production in Copper"
David Jones, Daniel Martinez, Calvin Lear, Jeremy Payton, Saryu Fensin,
[2020]
Materials
· DOI: 10.3390/ma13061270
The effect of helium (He) concentration on ejecta production in OFHC-Copper was investigated using Richtmyer–Meshkov Instability (RMI) experiments. The experiments involved complex samples with periodic surface perturbations machined onto the surface. Each of the four target was implanted with a unique helium concentration that varied from 0 to 4000 appm. The perturbation’s wavelengths were λ ≈ 65 μ m, and their amplitudes h 0 were varied to determine the wavenumber ( 2 π / λ ) amplitude product k h 0 at which ejecta production beganfor Cu with and without He. The velocity and mass of the ejecta produced was quantified using Photon Doppler Velocimetry (PDV) and Lithium-Niobate (LN) pins, respectively. Our results show that there was an increase of 30% in the velocity at which the ejecta cloud was traveling in Copper with 4000 appm as compared to its unimplanted counterpart. Our work also shows that there was a finer cloud of ejecta particles that was not detected by the PDV probes but was detected by the early arrival of a “signal” at the LN pins. While the LN pins were not able to successfully quantify the mass produced due to it being in the solid state, they did provide information on timing. Our results show that ejecta was produced for a longer time in the 4000 appm copper. |
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"Irradiation assisted stress corrosion cracking of commercial and advanced alloys for light water reactor core internals" Miao Song, Calvin R. Lear, Gary S. Was, Mi Wang, [2019] Journal of Nuclear Materials · DOI: 10.1016/j.jnucmat.2018.12.015 · ISSN: 0022-3115 | |
"Dual ion irradiation of commercial and advanced alloys: Evaluating microstructural resistance for high dose core internals" M. Song, M. Wang, G.S. Was, C.R. Lear, [2019] Journal of Nuclear Materials · DOI: 10.1016/j.jnucmat.2019.01.014 · ISSN: 0022-3115 | |
"Unusual irradiation-induced disordering in Cu3Au near the critical temperature: An in situ study using electron diffraction" Robert S. Averback, Pascal Bellon, Andrea E. Sand, Marquis A. Kirk, Calvin Robert Lear, [2018] Journal of Materials Research · DOI: 10.1557/jmr.2018.308 · ISSN: 0884-2914 | |
"Radiation tolerance of commercial and advanced alloys for core internals: a comprehensive microstructural characterization" Calvin R. Lear, Chad M. Parish, Mi Wang, Gary S. Was, Miao Song, [2018] Journal of Nuclear Materials · DOI: 10.1016/j.jnucmat.2018.08.035 · ISSN: 0022-3115 | |
"Probing long-range ordering in nickel-base alloys with proton irradiation" Ying Yang, Mi Wang, Wenjun Kuang, Calvin R. Lear, Gary S. Was, Miao Song, [2018] Acta Materialia · DOI: 10.1016/j.actamat.2018.06.043 · ISSN: 1359-6454 | |
"Novel mechanism for order patterning in alloys driven by irradiation" P. Bellon, R. S. Averback, C. R. Lear, [2017] Physical Review B · DOI: 10.1103/physrevb.96.104108 · ISSN: 2469-9950 | |
"Irradiation-induced creep in metallic nanolaminates characterized by In situ TEM pillar nanocompression" Daniel C. Bufford, Gowtham S. Jawaharram, Xuying Liu, Calvin Lear, Khalid Hattar, Robert S. Averback, Shen J. Dillon, [2017] Journal of Nuclear Materials · DOI: 10.1016/j.jnucmat.2017.04.008 · ISSN: 0022-3115 | |
"Irradiation-Induced Nanoprecipitation in Ni-W Alloys" Calvin R. Lear, Xuan Zhang, Pascal Bellon, Robert S. Averback, Jaeyel Lee, [2014] Metallurgical and Materials Transactions A · DOI: 10.1007/s11661-014-2704-4 · ISSN: 1073-5623 | |
Source: ORCID/CrossRef using DOI |
The Nuclear Science User Facilities (NSUF) is the U.S. Department of Energy Office of Nuclear Energy's only designated nuclear energy user facility. Through peer-reviewed proposal processes, the NSUF provides researchers access to neutron, ion, and gamma irradiations, post-irradiation examination and beamline capabilities at Idaho National Laboratory and a diverse mix of university, national laboratory and industry partner institutions.
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