Hyosim Kim

The functionality of nuclear structural materials, sensors, and microelectronics in harsh environments such as radiation relies on understanding defect generation and evolution processes in oxide layers. The initial radiation response of epitaxial thin films of Fe₃O₄(111), Cr₂O₃(0001), and Fe₃O₄(111)/Cr₂O₃(0001) heterostructures deposited on Al₂O₃(0001) by oxygen‐assisted molecular beam epitaxy and irradiated with 200 keV He⁺ is characterized. X‐ray diffraction and X‐ray absorption near edge spectroscopy showed that the Cr₂O₃ layers underwent significant lattice expansion and disordering under irradiation, whereas the Fe₃O₄ layers do not exhibit noticeable changes. In contrast, positron annihilation spectroscopy revealed an evolution of cation vacancy point defects in the Fe₃O₄ layers into larger vacancy clusters with increasing irradiation, while the cation vacancies in Cr₂O₃ remained primarily as single vacancies and small clusters. The results suggest that the Fe₃O₄ lattice can utilize the free volume of the larger vacancy clusters to relax but the small vacancies in the Cr₂O₃ lattice do not facilitate relaxation. Comparing defect concentrations in the single layer films versus the heterostructure suggests that point defects may cross the interface from Fe₃O₄ into Cr₂O₃. Together, these results enhance the understanding of the initial defect evolution mechanisms in oxide layers in harsh irradiation environments.

Additive friction stir deposition (AFS-D) is considered a productive method of additive manufacturing (AM) due to its ability to produce dense mechanical parts at a faster deposition rate compared to other AM methods. Al6061 alloy finds extensive application in aerospace and nuclear engineering; nevertheless, exposure to radiation or high-energy particles over time tends to deteriorate their mechanical performance. However, the effect of radiation on the components manufactured using the AFS-D method is still unexamined. In this work, samples from the as-fabricated Al6061 alloy, by AFS-D, and the Al6061 feedstock rod were irradiated with He+ ions to 10 dpa at ambient temperature. The microstructural and mechanical changes induced by irradiation of He+ were examined using a scanning electron microscope (SEM), energy-dispersive X-ray spectroscopy (EDS), transmission electron microscopy (TEM), and nanoindentation. This study demonstrates that, at 10 dpa of irradiation damage, the feedstock Al6061 produced a bigger size of He bubbles than the AFS-D Al6061. Nanoindentation analysis revealed that both the feedstock Al6061 and AFS-D Al6061 samples have experienced radiation-induced hardening. These studies provide a valuable understanding of the microstructural and mechanical performance of AFS-D materials in radiation environments, offering essential data for the selection of materials and processing methods for potential application in aerospace and nuclear engineering.

The stability of structural materials in extreme nuclear reactor environments—with high temperature, high radiation, and corrosive media—directly affects the lifespan of the reactor. In such extreme environments, an oxide layer on the metal surface acts as a passive layer protecting the metal underneath from corrosion. To predict the irradiation effect on the metal layer in these metal/oxide bilayers, nondestructive depth-resolved positron annihilation lifetime spectroscopy (PALS) and complementary transmission electron microscopy (TEM) were used to investigate small-scale defects created by ion irradiation in an epitaxially grown (100) Fe film capped with a 50 nm Fe2O3 oxide layer. In this study, the evolution of induced vacancies was monitored, from individual vacancy formation at low doses—10−5 dpa—to larger vacancy cluster formation at increasing doses, showing the sensitivity of positron annihilation spectroscopy technique. Furthermore, PALS measurements reveal how the presence of a metal–oxide interface modifies the distribution of point defects induced by irradiation. TEM measurements show that irradiation induced dislocations at the interface is the mechanism behind the redistribution of point defects causing their accumulation close to the interface. This work demonstrates that the passive oxide layers formed during corrosion impact the distribution and accumulation of radiation induced defects in the metal underneath and emphasizes that the synergistic impact of radiation and corrosion will differ from their individual impacts.

Small disks are often the specimen of choice for exposure in nuclear reactor environments, and this geometry invariably limits the types of mechanical testing that can be performed on the specimen. Recently, shear punch testing has been utilized to evaluate changes arising from neutron irradiation in test reactor environments on these small disk specimens. As part of a broader effort to link accelerated testing using ion irradiation and conventional neutron irradiation techniques, a novel microshear specimen geometry was developed for use with heavy-ion irradiated specimens. The technique was demonstrated in pure Cu irradiated to 11 and 110 peak dpa with 10 MeV Cu ions. At 11 peak dpa, the Cu specimen had a high density of small voids in the irradiated region, while at 110 peak dpa, larger voids with an average void swelling of ~20% were observed. Micropillar and microshear specimens both exhibited hardening at 11 dpa, followed by softening at 110 dpa. The close alignment of the new microshear technique and more conventional micropillar testing, and the fact that both follow intuition, is a good first step towards applying microshear testing to a wider range of irradiated materials.

This work highlights some limitations of thermal stability analysis via in-situ transmission electron microscopy (TEM)-annealing experiments on ultrafine and nanocrystalline materials. We provide two examples, one on nanocrystalline pure copper and one on nanocrystalline HT-9 steel, where in-situ TEM-annealing experiments are compared to bulk material annealing experiments. The in-situ TEM and bulk annealing experiments demonstrated different results on pure copper but similar output in the HT-9 steel. The work entails discussion of the results based on literature theoretical concepts, and expound on the inevitability of comparing in-situ TEM annealing experimental results to bulk annealing when used for material thermal stability assessment.

This work highlights some limitations of thermal stability analysis via in-situ transmission electron microscopy (TEM)-annealing experiments on ultrafine and nanocrystalline materials. We provide two examples, one on nanocrystalline pure copper and one on nanocrystalline HT-9 steel, where in-situ TEM-annealing experiments are compared to bulk material annealing experiments. The in-situ TEM and bulk annealing experiments demonstrated different results on pure copper but similar output in the HT-9 steel. The work entails discussion of the results based on literature theoretical concepts, and expound on the inevitability of comparing in-situ TEM annealing experimental results to bulk annealing when used for material thermal stability assessment.

Beyond the current commercial materials, refining the grain size is among the proposed strategies to manufacture resilient materials for industrial applications demanding high resistance to severe environments. Here, large strain machining (LSM) was used to manufacture nanostructured HT-9 steel with enhanced thermal stability, mechanical properties, and ductility. Nanocrystalline HT-9 steels with different aspect rations are achieved. In-situ transmission electron microscopy annealing experiments demonstrated that the nanocrystalline grains have excellent thermal stability up to 700 °C with no additional elemental segregation on the grain boundaries other than the initial carbides, attributing the thermal stability of the LSM materials to the low dislocation densities and strains in the final microstructure. Nano-indentation and micro-tensile testing performed on the LSM material pre- and post-annealing demonstrated the possibility of tuning the material’s strength and ductility. The results expound on the possibility of manufacturing controlled nanocrystalline materials via a scalable and cost-effective method, albeit with additional fundamental understanding of the resultant morphology dependence on the LSM conditions.

Plasma nitridation was conducted to modify the surfaces of Zircaloy-4. Scanning electron microscopy (SEM), transmission electron microscopy (TEM), and Raman analysis were used to characterize microstructures and phases. Surface indentation and cross-sectional indentation were performed to evaluate mechanical property changes. Nitridation forms a thin layer of ZrN phase, followed by a much deeper layer affected by nitrogen diffusion. The ZrN phase is confirmed by both TEM and Raman characterization. The Raman peaks of ZrN phase show a temperature dependence. The intensity increases with increasing nitridation temperatures, reaches a maximum at 700 °C, and then decreases at higher temperatures. The ZrN layer appears as continuous small columnar grains. The surface polycrystalline ZrN phase is harder than the bulk by a factor of ~8, and the nitrogen diffusion layer is harder by a factor of ~2–5. The activation energy of nitrogen diffusion was measured to be 2.88 eV. The thickness of the nitrogen-hardened layer is controllable by changing the nitridation temperature and duration.

As one candidate alloy for future Generation IV and fusion reactors, a dual-phase 12Cr oxide-dispersion-strengthened (ODS) alloy was developed for high temperature strength and creep resistance and has shown good void swelling resistance under high damage self-ion irradiation at high temperature. However, the effect of helium and its combination with radiation damage on oxide dispersoid stability needs to be investigated. In this study, 120 keV energy helium was preloaded into specimens at doses of 1 × 1015 and 1 × 1016 ions/cm2 at room temperature, and 3.5 MeV Fe self-ions were sequentially implanted to reach 100 peak displacement-per-atom at 475 °C. He implantation alone in the control sample did not affect the dispersoid morphology. After Fe ion irradiation, a dramatic increase in density of coherent oxide dispersoids was observed at low He dose, but no such increase was observed at high He dose. The study suggests that helium bubbles act as sinks for nucleation of coherent oxide dispersoids, but dispersoid growth may become difficult if too many sinks are introduced, suggesting that a critical mass of trapping is required for stable dispersoid growth.

We studied the effects of internal free surfaces on the evolution of ion-induced void swelling in pure iron. The study was initially driven by the motivation to introduce a planar free-surface defect sink at depths that would remove the injected interstitial effect from ion irradiation, possibly enhancing swelling. Using the focused ion beam technique, deep trenches were created on a cross section of pure iron at various depths, so as to create bridges of thickness ranging from 0.88 μm to 1.70 μm. Samples were then irradiated with 3.5 MeV Fe2+ ions at 475 °C to a fluence corresponding to a peak displacement per atom dose of 150 dpa. The projected range of 3.5 MeV Fe2+ ions is about 1.2 μm so the chosen bridge thicknesses involved fractions of the ion range, thicknesses comparable to the mean ion range (peak of injected interstitial distribution), and thicknesses beyond the full range. It was found that introduction of such surfaces did not enhance swelling but actually decreased it, primarily because there were now two denuded zones with a combined stronger influence than that of the injected interstitial. The study suggests that such strong surface effects must be considered for ion irradiation studies of thin films or bridge-like structures.