Oxide Dispersion Strengthened Steel Research Articles

Practical Design of a Breed-and-Burn Lead-Cooled Fast Reactor with Rotational Fuel Shuffling Strategy

The purpose of this study is to demonstrate a practical core design for a lead-cooled, nitride fueled, rotational fuel shuffling breed-and-burn (RFBB) fast reactor. The core design is based on the Westinghouse Lead Fast Reactor (WH-LFR) and uses natural uranium nitride fuel with a sodium bond encased in oxide dispersion-strengthened steel cladding. Simulations confirmed the potential of the reactor to maintain criticality at the equilibrium state, with a reactivity swing of less than 200 pcm at every cycle interval and an average discharge burnup of 235 MWd/kg heavy metals (HM) for a 1050 effective full-power day refueling interval. Power profiles were maintained stable at the equilibrium state, while the cladding of the discharged fuel incurred over 650 displacements per atom over its entire residency in the core. From a nonproliferation perspective, the plutonium vector for the discharge fuel aligns with reactor-grade fuel standards, with over a 70% concentration of 239Pu and over 22% 240Pu, reducing the risk of weaponization. The adopted control rod system has been shown to offer sufficient negative reactivity of over 19 $ to bring the reactor into a subcritical state. Challenges such as the susceptibility of neutron balance to material thickness and neutron leakage have been addressed, emphasizing the necessity for meticulous design improvements. A steady-state thermohydraulic analysis confirmed the heat removal capacity from the hottest channel, ensuring operational safety. This study confirmed the feasibility of the RFBB strategy for a lead-cooled nitride-fueled fast reactor and sets a precedent for future research in enhancing fuel utilization and safety in nuclear reactors.

New dispersion mechanism for oxide dispersion-strengthened steels by liquid metallurgy

The use of oxide dispersion-strengthened (ODS) alloys in demanding applications can effectively reduce parts’ weights, extend life of use, and enhance overall energy efficiency. But, the current manufacturing of ODS alloys has remained impractical for decades due to poor scalability and extremely high costs. Mass production of ODS steels by liquid metallurgy is therefore crucial to decrease their costs by several orders of magnitude and expand their potential applications. However, oxide nanoparticle (NP) dispersion in molten alloys presents fundamental challenges for liquid metallurgy due to the vastly dissimilar atomic properties between ionocovalent oxides and metals. Here we show, for the first time, that Y2O3 NPs are able to be dispersed in liquid 316L with a 1 % Nb addition. It was discovered that Nb-enriched interfacial layers exist around the Y2O3 NPs in solidified steels after slow cooling. Theoretical analyses reveal that the Nb-enriched interfacial layer induces a higher energy barrier and a significantly lower van der Waals attraction between oxide NPs and liquid Fe for the successful dispersion of oxide NPs in liquid steels. Moreover, Y2O3 and Al2O3 NPs were successfully dispersed in lean steels, such as Fe-Nb and low-C steels. This new dispersion mechanism of oxide NPs opens an exciting pathway for the economical mass manufacturing of various ODS alloys by liquid metallurgy for numerous applications.

The Effects of Irradiation on the Improvement in Oxidation Behavior of MX-ODS Steel in Liquid Pb.

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.

Manufacturing Oxide Dispersion Strengthened (ODS) steel plate via cold spray and friction stir processing

Oxide dispersion strengthened (ODS) steels, traditionally fabricated by ball milling and conventional powder metallurgy techniques to achieve bulk form, followed by intricate rolling and thermal treatment steps to achieve plate or sheet form. Here, we present a novel processing route that combines cold spray (CS) with friction stir processing (FSP) to manufacture ODS steel plate directly from gas atomization reaction synthesis (GARS)-prepared powder, thus no rolling steps involved. Microstructural and mechanical characterizations were performed to assess the quality and properties of the resulting ODS steel plate. Our findings demonstrate that the slightly porous CS deposited layer was fully consolidated after FSP, yielding a fully dense ODS steel plate that exhibited a favorable tradeoff between strength and ductility upon extraction from the substrate. Furthermore, through microstructural analysis, we revealed the presence of an appreciable density (∼1022/m3) of nano-sized oxide particles, with the majority being smaller than 5 nm via the combined CS + FSP fabrication route. This work serves as a first proof-of-concept demonstration of the manufacturing approach described herein, offering a possible alternative route for producing ODS steel plates.

Microstructure Evolution and Mechanical Properties of a High Cr Oxide Dispersion-Strengthened Steel through STARS Route Followed by Hot Isostatic Pressing

Microstructure Evolution and Mechanical Properties of a High Cr Oxide Dispersion-Strengthened Steel through STARS Route Followed by Hot Isostatic Pressing

Atomic Diffusivities of Yttrium, Titanium and Oxygen Calculated by Ab Initio Molecular Dynamics in Molten 316L Oxide-Dispersion-Strengthened Steel Fabricated via Additive Manufacturing.

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.

Softening mechanism and failure behavior of 9Cr oxide dispersion strengthened steel resistance spot welded joint

Oxide dispersion strengthened (ODS) steel is one of the most promising materials for nuclear applications. However, there are fewer studies on the spot welding of ODS steel, and the softening mechanism of ODS steel resistance spot welded joint is unclear. The microstructural features of the ODS resistance spot welded joint was characterized to analyze the softening mechanism. The failure behavior and tensile shear performance were studied combined with finite element simulation. The results showed that the fusion boundary has the lowest hardness and the softening zone is divided into fusion zone(FZ) softening and heat affected zone(HAZ) softening according to different location in the joint. In FZ softening, the softening is mainly caused by the presence of δ-ferrite and fewer oxides as well as lower dislocation density. In HAZ softening, the softening is mainly caused by larger grains, less oxides. There are two types of failure, the fracture initiated at HAZ softening shows a brittle feature, while initiated at FZ softening shows a ductile feature. The softening leads to a reduction in tensile-shear strength. Thus, the control of softening zone is critical to improve the reliability of welded joints.

The effect of chemical composition and heat parameter on Nano-sized precipitate dispersion characterization in ODS steels

Oxide dispersion strengthened (ODS) supersaturated solid solution alloy powders with different Y/Ti atomic ratios were formed by mechanical alloying (MA) method and then heat treated under different conditions. The morphology, phase composition, and particle size distribution were researched. The precipitate distribution densities and hardness values of alloy powders after heat treatment were measured at the same time by the SAXS method and hard tester. The results show that the morphology of MA alloy powders is irregular in shape and only a small amount of MA alloy powders is bigger than 30 μm. During the MA process, alloy elements are solid solutions in the matrix. The work-harden effect of alloy powders formed in the MA process would be eliminated during the heat treatment process. The chemical composition and heat treatment parameters are crucial effects on nano-sized precipitate distribution characterization in ODS steels. The ODS sample with a Y/Ti atomic ratio of 0.99 has the highest distribution density of oxide precipitates at 1.89×1022/m3 resulting in the highest hardness value during the heat treatment process. The sample with a Y/Ti atomic ratio of 0.42 has the highest distribution density of nanoclusters 7.32×1023/m3.

Effect of Interface Wettability on Additively Manufactured Metal Matrix Composites: A Case Study of 316L-Y2O3 Oxide Dispersion-Strengthened Steel

Laser powder bed fusion (LPBF) is a fusion-based additive manufacturing process. It has the advantage of allowing the manufacturing of metal matrix composites. This advantage arises from its small melting zone and rapid cooling rate, which minimize the risk of reinforcement segregation. In this work, 0.3 wt% and 1.0 wt% Y2O3 nanoparticles were added to 316L to fabricate oxide dispersion-strengthened (ODS) steels using the LPBF process. Notably, Y2O3 agglomerates were identified in the LPBF-fabricated 316L ODS steels, without inducing grain refinement, while the impact on tensile strength of Y2O3 addition proved negligible. Tensile elongation was decreased due to the poor bonding of the Y2O3 agglomerations to the matrix. The crucial role of the wettability of the reinforcement and the matrix in facilitating grain refinement and strength enhancement is discussed. The poor wettability of the Y2O3 particles and 316L emerged as the primary cause for Y2O3 agglomeration. This finding highlights the importance of addressing wettability issues to optimize the manufacturing process and enhance the overall performance of LPBF-fabricated metal matrix composites.

Study of Precipitates in Oxide Dispersion-Strengthened Steels by SANS, TEM, and APT.

In this work, the nanostructure of oxide dispersion-strengthened steels was studied by small-angle neutron scattering (SANS), transmission electron microscopy (TEM), and atom probe tomography (APT). The steels under study have different alloying systems differing in their contents of Cr, V, Ti, Al, and Zr. The methods of local analysis of TEM and APT revealed a significant number of nanosized oxide particles and clusters. Their sizes, number densities, and compositions were determined. A calculation of hardness from SANS data collected without an external magnetic field, or under a 1.1 T field, showed good agreement with the microhardness of the materials. The importance of taking into account two types of inclusions (oxides and clusters) and both nuclear and magnetic scattering was shown by the analysis of the scattering data.

Development of a Diffusion Bonding Route for Joining Oxide-Dispersion-Strengthened (ODS) Steels for Nuclear Applications

Oxide-dispersion-strengthened (ODS) steels are candidate materials for components in current and future nuclear power plants. One of the issues with using ODS steels is the difficulty of joining them without loss of mechanical performance. In this study, austenitic ODS 316L stainless steel was diffusion-bonded to Inconel 718 superalloy. Having optimized the bonding conditions, a number of samples were made at 1200 °C with a bonding time of 1 hour and pressure of 10 MPa. Preliminary mechanical and microstructural analyses indicated the formation of a sound joint interface, despite slight grain growth in the ODS 316L. A post-bonding thermo-mechanical treatment (TMT) was conducted to refine and restore the microstructure of the ODS 316L. Comparative TEM investigations of the parent ODS alloy and the bonded samples (with and without TMT) along with statistical analyses showed that the Y–Ti–O oxide size distribution remains unaffected by the bonding and complementary TMT cycles, indicating stability of such particles even at very high temperatures and suitability of the devised route for joining the ODS 316L steel.

A Study of the Effect of Magnetic Scattering on the Analysis of the Nanostructure of Oxide Dispersion-Strengthened Steels by Small-Angle Neutron Scattering

A Study of the Effect of Magnetic Scattering on the Analysis of the Nanostructure of Oxide Dispersion-Strengthened Steels by Small-Angle Neutron Scattering

Effects of Cr and Si addition on the high-temperature oxidation resistance in high-Mn alumina-forming oxide dispersion strengthened austenitic steels

Oxide dispersion-strengthened (ODS) steels are promising candidates for constructing nuclear reactors. Considering a high-temperature environment, ODS austenitic steels could provide superior performance compared to the current ODS ferritic steels. To meet the reduced activation requirement, the compositions of ODS austenitic steels have to be carefully adjust. Currently, the authors focus on the ODS austenitic steels with the austenite stabilizer of Mn, and several amounts of Al are added to improve their high-temperature oxidation resistance. This study investigates the third-element effects of Cr and Si on the high-temperature oxidation resistance of high-manganese alumina-forming ODS austenitic steels. Generally, Si-containing steel exhibits superior oxidation resistance owing to the formation of a continuous inner layer of amorphous alumina. In contrast, the Cr-containing steel does not possess a continuous alumina layer, resulting in insufficient oxidation resistance. The reported phenomenon is believed to be a reference for the development of ODS austenitic steels in the future.

Optimization of microstructure and tensile properties for a 13Cr-1W ODS steel prepared by mechanical alloying and spark plasma sintering using pre-alloyed powder

An oxide-dispersion-strengthened (ODS) 13Cr-1W steel has been fabricated through mechanical alloying (MA) and spark plasma sintering (SPS) using pre-alloyed Fe-Cr-W-Y powder and TiO2 powder. Sufficient MA effects, indicated by homogeneous distribution of alloying elements and high level of lattice strain inside the powder, have been obtained within 20 h of high-energy ball-milling. Grain refinement of the bulk materials is successfully achieved by optimizing the sintering temperature and pressure during SPS. A fine-grained ODS steel with average grain size of 626.75 nm is prepared when sintered at 950 °C/80 MPa. Ultrafine oxide dispersoids, identified as Y2O3, Y2TiO5 and Y2Ti2O7, are observed homogeneously distributed in the steel matrix after annealing. They have a number density of 4.5 × 1022 m−3 and an average size of 11.15 nm. Tensile tests from room temperature to 700 °C are conducted to this ODS steel. It exhibits an ultimate tensile strength and a yield strength of 1559.60 MPa and 1352.82 MPa at room temperature, respectively. Due to a good combination of dislocation strengthening, grain boundary strengthening and precipitation strengthening, this alloy wins superior tensile properties over most of the commercial ODS steels and those reported in some previous studies.

Study of the Nanostructure of Oxide Dispersion-Strengthened Steels with Small-Angle Neutron Scattering

Study of the Nanostructure of Oxide Dispersion-Strengthened Steels with Small-Angle Neutron Scattering

Comprehensive Study of the Impact of Iron-Ion Irradiation at 500°C on the Nanostructure of Oxide Dispersion-Strengthened Steels

Comprehensive Study of the Impact of Iron-Ion Irradiation at 500°C on the Nanostructure of Oxide Dispersion-Strengthened Steels

Study of Nanostructures in High-Chromium Oxide Dispersion-Strengthened Steels

Study of Nanostructures in High-Chromium Oxide Dispersion-Strengthened Steels

Uncertainty and statistics of dislocation-oxide interactions on strength and creep failure of oxide dispersion strengthened steels

Oxide dispersion strengthening (ODS) steels exhibit excellent mechanical and creep properties due to the nanoscale oxide particles as barriers to dislocation motion, for the great application potentials to structural components of advanced nuclear power plants. However, the classical ODS model described by the Orowan mechanism or cutting mechanism only depends upon a single average size, ignoring uncertainty and statistics of dislocation-oxide interactions induced by the spatial and dimensional random distribution of oxide particles. When the oxide particle size is larger than the critical size to determine the interaction mechanism transformation from cutting to looping, the Orowan mechanism and cutting mechanism would exist simultaneously. Here we propose a modified ODS model for strength and creep rate considering the spatial distribution and size distribution of oxide particles, which is more consistent with the experimental result compared to the classical ODS model. In addition, the contribution of oxide particles to the yield strength and creep strength is evaluated quantitatively for various precipitate sizes and volume fractions. It is believed that this model provides an analytical framework to accurately predict the strength and creep rate of ODS steels.

On the nanoscale oxide dispersion via in-situ atmospheric oxidation during laser powder bed fusion

In-situ oxidation during laser additive manufacturing (AM) is considered a more economical approach to producing AM oxide dispersion-strengthened (ODS) alloys. However, there is very few success in making AM ODS alloys with oxide density comparable to commercial ODS alloys made by conventional means. To explore the key mechanisms that prevent the high-density dispersion of nanoscale oxides during in-situ reactive AM, we investigated oxide dispersion by in-situ gas-phase reaction during laser powder bed fusion (LPBF) with respect to oxygen gettering elements with different oxygen affinity, getter concentration, atmospheric oxygen level, and laser parameters. Our results show that in-situ oxidation in a high-oxygen printing atmosphere during LPBF AM cannot effectively produce good-quality ODS steels, even when the amount of oxygen pick-up from the atmosphere into the melt pool is comparable to the oxygen level in commercial ODS alloys. We found that surface oxidation and oxide agglomeration in the melt pool prevent the high-density dispersion of nanoscale oxides. In addition, oxide agglomeration also contributes to a higher amount of manufacturing defects. Powder spattering plays a secondary impact on oxygen loss.

Effect of directional anisotropy on mechanical properties of 9Cr Ferritic/Martensitic ODS steels processed by mechanical alloying and powder forging

The present work investigates the feasibility of the powder forging route as a novel approach for the consolidation of oxide dispersion strengthened (ODS) steel powders. Mechanically alloyed powder of the composition Fe-9Cr-2 W-0.2Ti-0.12 C-0.35Y2O3 was filled in a mild steel can and loose sintered in a reducing atmosphere at 1200 °C after which it was forged in a channel die using a friction screw forging machine. The forged ODS steel was investigated in terms of residual porosity, microstructure, hardness and tensile properties. Density as well as hardness variation was determined along both the forging directions, i.e., longitudinal and transverse. In the transverse direction density, hardness and tensile strength was slightly higher as compared to that in the longitudinal direction. Powder forging led to the elimination of the prior particle boundaries (PPB) network in the final forged slab. Further, near isotropic mechanical properties and homogeneous chemical composition were obtained throughout the forged sample. The proposed powder forging route has significant potential as an alternative consolidation process to hot isostatic pressing (HIP) and hot extrusion to produce ODS steel for nuclear applications.