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This study aims to predict the creep response of Alloy 617 and assess the accuracy of three established creep damage models in predicting the creep time-to-failure (tf) and strain-to-failure (εf) in the temperature range of 800–1000 °C. Idaho National Laboratory (INL) creep data were used to calibrate (1) Ductility Exhaustion (DE), (2) Stress-Modified Ductility Exhaustion (SMDE), and (3) Strain-Energy Density (SED) creep damage models using multiple linear regression (LR) and reverse damage (RD) approaches. In order to predict the creep response of Alloy 617 these creep damage models are then coupled with (secondary) creep strain model calibrated using Idaho National Laboratory (INL), Korean Atomic Energy Research Institute (KAERI), and Argonne National Laboratory (ANL) experimental data. Direct comparisons made between the investigated creep damage models revealed that the SED model with parameters calibrated through RD approach captures the creep response of Alloy 617 the most accurately and it thus produces the most accurate prediction of time-to-failure (tf) and strain-to-failure (εf) across different temperature/stress (creep) conditions. However, it is also shown that none of the employed creep damage models are able to fully capture the material creep response at 1000 °C. This is attributed the strong oxidation of Alloy 617 at 1000 °C (tested in air) leading to the formation of a thick oxidation layer, which might affect the failure mechanism of the alloy at this temperature.

Interactions between stainless steel 316L and eutectic Li2CO3 + K2CO3 + Na2CO3 at 450 °C were investigated for thermal energy storage. Scanning Electron Microscopy (SEM), Electron Back-Scatter Diffraction (EBSD), Scanning Kelvin Probe Force Microscopy (SKPFM), X-ray Photoelectron Spectroscopy (XPS), neutron diffraction pattern, material loss, micro-hardness, polarization and impedance measurements were used to compare the alloy's response in unrolled (0%) condition versus 20% and 30% cold-rolled conditions. Cold-rolling increased the number of grains, grain boundaries and density of dislocations. Initially, faster corrosion accompanied by more areas of localized attack was confirmed by Volta potential measurements. However, recovery and the formation of a surface film were found to decelerate corrosion for longer times. Cold-rolling-induced dislocations were found to facilitate carbon diffusion and subsequently carburize the material leading to increased corrosion resistance. Consequently, the overall long-time corrosion rate was not noticeably affected by cold-rolling.

The Hall–Petch relation has long been used to relate the yield strength of a metal to its grain sizes in which the effectiveness of grain size strengthening in the metal is dictated by the Hall–Petch coefficient (slope). Therefore, understanding the microstructural dependence of the Hall–Petch slope would be very useful in designing new high-strength ultrafine grained (UFG) metallic materials. In this study, we investigated the microstructural factors affecting the Hall–Petch slope in UFG Al-Mg alloys with an average grain size range from 374 to 639 nm and different Mg contents of 0, 2.5, 5, and 7.5 at. pct. The rods prepared by extrusion of mechanically alloyed powder compacts were annealed for 5 hours at 380 °C, 420 °C, and 500 °C respectively followed by water quenching to produce the alloy samples in this study. The measured Hall–Petch slopes of the samples were found to increase with increasing Mg content and had higher values than those previously reported for Al(Mg) solid solutions with Mg concentrations comparable to the Mg contents in this study. Analysis of X-ray diffraction, transmission electron microscopy, and atom probe tomography experimental data as well as strengthening mechanisms demonstrates that the formation of nanoscale MgO dispersions plays a major role in the improved Hall–Petch slope observed in Al-Mg alloys.

© 2017 Acta Materialia Inc. Interactions between neighboring grains influence the macroscale behavior of polycrystalline materials, particularly their deformation behavior, damage initiation and propagation mechanisms. However, mapping all of the critical material properties normally requires that several independent measurements are performed. Here we report the first grain mapping of a polycrystalline foil using a pixelated energy-dispersive X-ray area detector, simultaneously measuring X-ray fluorescence and diffraction with the Maia detector in order to determine grain orientation and estimate lattice strain. These results demonstrate the potential of the next generation of X-ray area detectors for materials characterization. By scanning the incident X-ray energy we investigate these detectors as a complete solution for simultaneously mapping the crystallographic and chemical properties of the sample. The extension of these techniques to broadband X-ray sources is also discussed.

© 2017 by the authors. A new generation of alloys, which rely on a combination of various strengthening mechanisms, has been developed for application in molten salt nuclear reactors. In the current study, a battery of dispersion and precipitation-strengthened (DPS) NiMo-based alloys containing varying amounts of SiC (0.5-2.5 wt %) were prepared from Ni-Mo-SiC powder mixture via a mechanical alloying (MA) route followed by spark plasma sintering (SPS) and rapid cooling. Neutron Powder Diffraction (NPD), Electron Back Scattering Diffraction (EBSD), and Transmission Electron Microscopy (TEM) were employed in the characterization of the microstructural properties of these in-house prepared NiMo-SiC DPS alloys. The study showed that uniformly-dispersed SiC particles provide dispersion strengthening, the precipitation of nano-scale Ni3Si particles provides precipitation strengthening, and the solid-solution of Mo in the Ni matrix provides solid-solution strengthening. It was further shown that the milling time has significant effects on the microstructural characteristics of these alloys. Increasedmilling time seems to limit the grain growth of theNiMomatrix by producing well-dispersed Mo2C particles during sintering. The amount of grain boundaries greatly increases the Hall-Petch strengthening, resulting in significantly higher strength in the case of 48-h-milled NiMo-SiC DPS alloys compared with the 8-h-milled alloys. However, it was also shown that the total elongation is considerably reduced in the 48-h-milled NiMo-SiC DPS alloy due to high porosity. The porosity is a result of cold welding of the powder mixture during the extended milling process.

Recent experimental work has shown residual stress measurements in welded material to be difficult. To better assess the precision of residual stress measurement techniques, a measurement article was designed to allow repeated measurements of a nominally identical stress field. The measurement article is a long 316L stainless steel plate containing a machine-controlled eight-pass slot weld. Measurements of weld direction residual stress made with the contour method found high tensile stress in the weld and heat-affected zone, with a maximum near 450 MPa and compressive stress away from the weld, a typical residual stress profile for constrained welds. The repeatability standard deviation of repeated contour method residual stress measurements was found to be less than 20 MPa at most spatial locations away from the boundaries of the plate. The repeatability data in the weld are consistent with those from a previous repeatability experiment using the contour method in quenched aluminum bars. A finite-element simulation and neutron diffraction measurements were performed for the same weld and provided results consistent with the contour method measurements. Much of the material used in the work remains available for use in assessing other residual stress measurement techniques, or for an interlaboratory reproducibility study of the contour method.

This paper describes a sequence of residual stress measurements made to determine a two-dimensional map of biaxial residual stress in a stainless steel weld. A long stainless steel (316L) plate with an eight-pass groove weld (308L filler) was used. The biaxial stress measurements follow a recently developed approach, comprising a combination of contour method and slitting measurements, with a computation to determine the effects of out-of-plane stress on a thin slice. The measured longitudinal stress is highly tensile in the weld- and heat-affected zone, with a maximum around 450 MPa, and compressive stress toward the transverse edges around −250 MPa. The total transverse stress has a banded profile in the weld with highly tensile stress at the bottom of the plate (y = 0) of 400 MPa, rapidly changing to compressive stress (at y = 5 mm) of −200 MPa, then tensile stress at the weld root (y = 17 mm) and in the weld around 200 MPa, followed by compressive stress at the top of the weld at around −150 MPa. The results of the biaxial map compare well with the results of neutron diffraction measurements and output from a computational weld simulation.

The present work examines optimal cutting configurations for the measurement of weld residual stresses (WRS) using the contour method. The accuracy of a conventional, single-cut configuration that employs rigid clamping is compared with novel, double-embedded cutting configurations that rely on specimen self-constraint during cutting. Numerical analyses examine the redistribution of WRS and the development of cutting-induced plasticity (CIP) in a three-pass austenitic slot weld (NeT TG4) during the cutting procedure for each configuration. Stress intensity factor (SIF) analyses are first used as a screening tool; these analyses characterise lower stress intensities near the cutting surface when double-embedded cutting configurations are used, relative to SIF profiles from a single-cut process. The lower stress intensities indicate the development of CIP – which will ultimately affect back-calculated WRS – is less likely to occur when using an embedded configuration. The improvements observed for embedded cutting approaches are confirmed using three-dimensional finite element (FE) cutting simulations. The simulations reveal significant localised plasticity that forms in the material ligaments located between the pilot holes and the outer edges of the specimen. This plasticity is caused by WRS redistribution during the cutting process. The compressive plasticity in these material ligaments is shown to reduce the overall tensile WRS near the weld region before this region is sectioned, thereby significantly reducing the amount of CIP when cutting through the weld region at a later stage of the cutting procedure. Further improvements to the embedded cutting configuration are observed when the equilibrating compressive stresses in material ligaments are removed entirely (via sectioning) prior to sectioning of the high WRS region in the vicinity of the weld. All numerical results are validated against a series of WRS measurements performed using the contour method on a se

An assessment of cutting-induced plasticity (CIP) is performed, by finite element (FE) prediction of the plastic strain accumulation along the cut tip when the EDM wire sections the NeT TG4 weld benchmark specimen along two cutting directions. The first direction corresponds to a conventional (C) cutting strategy, whereby the EDM wire cuts through the thickness of the weld specimen and travels in a direction transverse to the weld. The second direction corresponds to a self-equilibrating cutting (SE) strategy, whereby the EDM wire cuts across the transverse direction of the weld specimens and travels through the thickness of the plate. The cutting thus progresses simultaneously through the compression-tension-compression regions of present weld residual stress (WRS) field. This type of cutting strategy is believed to minimize the CIP by minimising residual stress redistribution during cutting, due to stress equilibration across the sectioned material. The simulated cutting procedures are conducted under a range of clamping conditions to assess whether mechanical restraint has a primary or secondary influence on CIP accumulation. Both predictions of CIP and the resultant back-calculated WRS demonstrate that (i) mechanical restraint is the primary variable influencing CIP development, and (ii) under no circumstance does a self-equilibrating cutting strategy perform significantly better than a conventional cutting approach. The reason that self-equilibrating cuts are not effective is illustrated by calculating the Mode I (KI) stress intensity factor (SIF) along the cut tip, and correlating trends in KI to CIP development.

The present work examines optimal cutting configurations for the measurement of weld residual stresses (WRS) using the contour method. The accuracy of a conventional, single-cut configuration that employs rigid clamping is compared with novel, double-embedded cutting configurations that rely on specimen self-constraint during cutting. Numerical analyses examine the redistribution of WRS and the development of cutting-induced plasticity (CIP) in a three-pass austenitic slot weld (NeT TG4) during the cutting procedure for each configuration. Stress intensity factor (SIF) analyses are first used as a screening tool; these analyses characterise lower stress intensities near the cutting surface when double-embedded cutting configurations are used, relative to SIF profiles from a single-cut process. The lower stress intensities indicate the development of CIP – which will ultimately affect back-calculated WRS – is less likely to occur when using an embedded configuration. The improvements observed for embedded cutting approaches are confirmed using three-dimensional finite element (FE) cutting simulations. The simulations reveal significant localised plasticity that forms in the material ligaments located between the pilot holes and the outer edges of the specimen. This plasticity is caused by WRS redistribution during the cutting process. The compressive plasticity in these material ligaments is shown to reduce the overall tensile WRS near the weld region before this region is sectioned, thereby significantly reducing the amount of CIP when cutting through the weld region at a later stage of the cutting procedure. Further improvements to the embedded cutting configuration are observed when the equilibrating compressive stresses in material ligaments are removed entirely (via sectioning) prior to sectioning of the high WRS region in the vicinity of the weld. All numerical results are validated against a series of WRS measurements performed using the contour method on a se

An assessment of cutting-induced plasticity (CIP) is performed, by finite element (FE) prediction of the plastic strain accumulation along the cut tip when the EDM wire sections the NeT TG4 weld benchmark specimen along two cutting directions. The first direction corresponds to a conventional (C) cutting strategy, whereby the EDM wire cuts through the thickness of the weld specimen and travels in a direction transverse to the weld. The second direction corresponds to a self-equilibrating cutting (SE) strategy, whereby the EDM wire cuts across the transverse direction of the weld specimens and travels through the thickness of the plate. The cutting thus progresses simultaneously through the compression-tension-compression regions of present weld residual stress (WRS) field. This type of cutting strategy is believed to minimize the CIP by minimising residual stress redistribution during cutting, due to stress equilibration across the sectioned material. The simulated cutting procedures are conducted under a range of clamping conditions to assess whether mechanical restraint has a primary or secondary influence on CIP accumulation. Both predictions of CIP and the resultant back-calculated WRS demonstrate that (i) mechanical restraint is the primary variable influencing CIP development, and (ii) under no circumstance does a self-equilibrating cutting strategy perform significantly better than a conventional cutting approach. The reason that self-equilibrating cuts are not effective is illustrated by calculating the Mode I (KI) stress intensity factor (SIF) along the cut tip, and correlating trends in KI to CIP development.