Terry C. Totemeier

Microstructure and stresses in HVOF sprayed iron aluminide coatings

The microstructure and state of stress present in Fe3Al coatings produced by high velocity oxygen fuel (HVOF) thermal spraying in air at varying particle velocities were characterized using metallography, curvature measurements, x-ray analysis, and microhardness measurements. Sound coatings were produced for all conditions. The microstructures of coatings prepared at higher velocities showed fewer unmelted particles and a greater extent of deformation. Residual stresses in the coatings were compressive and varied from nearly zero at the lowest velocity to approximately −450 MPa at the highest velocity. X-ray line broadening analyses revealed a corresponding increase in the extent of cold work present in the coating, which was also reflected in increased microhardness. Values of mean coefficient of thermal expansion obtained for assprayed coatings using x-ray analysis were significantly lower than those for powder and bulk alloy.

Effect of high-velocity oxygen-fuel thermal spraying on the physical and mechanical properties of type 316 stainless steel

Data on the microstructural, physical, and mechanical characteristics of high-velocity oxygen-fuel (HVOF)-sprayed type 316 stainless steel coatings are presented and compared with properties of wrought 316 stainless steel. Coatings were prepared at three different spray particle velocities; coating characteristics are presented as a function of velocity. The coatings had relatively low porosity and oxide contents and were significantly harder than annealed, wrought 316 stainless steel. The hardness difference is primarily attributed to high dislocation densities resulting from peening imparted by high-velocity spray particles. The coating hardness increased with increasing spray particle velocity, reflecting increased peening effects. The elastic modulus of the coatings was essentially identical to wrought material. The mean coefficient of thermal expansion of as-sprayed coatings was lower than wrought material, but the expansion of annealed coatings matched the wrought behavior.

Development of a Supercritical Carbon Dioxide Brayton Cycle: Improving PBR Efficiency and Testing Material Compatibility - 2004 Annual Report

Generation IV reactors will need to be intrinsically safe, having a proliferation-resistant fuel cycle and several advantages relative to existing light water reactor (LWR). They, however, must still overcome certain technical issues and the cost barrier before it can be built in the U.S. The establishment of a nuclear power cost goal of 3.3 cents/kWh is desirable in order to compete with fossil combined-cycle, gas turbine power generation. This goal requires approximately a 30 percent reduction in power cost for stateof-the-art nuclear plants. It has been demonstrated that this large cost differential can be overcome only by technology improvements that lead to a combination of better efficiency and more compatible reactor materials. The objectives of this research are (1) to develop a supercritical carbon dioxide Brayton cycle in the secondary power conversion side that can be applied to the Very-High-Temperature Gas-Cooled Reactor (VHTR), (2) to improve the plant net efficiency by using the carbon dioxide Brayton cycle, and (3) to test material compatibility at high temperatures and pressures. The reduced volumetric flow rate of carbon dioxide due to higher density compared to helium will reduce compression work, which eventually increase plant net efficiency.

High-Temperature Creep-Fatigue of Alloy 617 Base Metal and Weldments

Creep-fatigue testing of nickel alloy 617 base metal and fusion weldments was performed at temperatures of 800 and 1000°C in air in support of ASME BPV Sec III code qualification of alloy 617 for the Next-Generation Nuclear Plant. Cyclic loading was performed in strain control with a trapezoidal waveform and was fully reversed. Creep was introduced into the fatigue cycle by a hold period at maximum tensile strain which varied from 18 to 9000 seconds. Base metal specimens were machined from 20 mm thick rolled plate; weldment specimens were machined from GTAW butt-welded plate such that the loading direction was oriented transverse to the welding direction. Weld metal, heat-affected zone, and base metal were present in the reduced section of weldment specimens. Creep-fatigue lives decreased with increasing hold time for both base metal and weldments; lives of weldments were reduced relative to those of base metal. Creep-fatigue cracking in weldment specimens initiated in the weld metal.