Laser powder bed fusion (LBFP) additive manufacturing is a potential route for the rapid qualification of new materials for use in nuclear reactor design. Process anomalies such as spatter particles can induce lack of fusion (LOF) voids that may adversely affect the material's mechanical performance. This examination of the spatter particle process in a nickel superalloy using X-ray computed tomography and optical microscopy was conducted to identify possible causes for the formation of LOF voids and other variations during LBPF processing.

AM&P spoke with Brian Donahue of Canvus to learn how this manufacturer upcycles end-of-life wind turbine blades into furniture for communities, parks, and schools.

The benefits and flexibility of using additive manufacturing (AM) open up new possibilities for lithium-ion battery design and performance beyond the limitations of traditional manufacturing methods. In particular, AM offers the ability to build on-demand complex geometries and shape-conformable battery components with tailored properties. While 3D printing offers significant potential, challenges include considerations related to feedstock consistency, printing parameters, and electrochemical performance of the printed components.

The development of polymers, traditionally neglected in fusion materials research, is crucial to the success of commercial fusion energy. This article provides an overview of the materials science and technology challenges that will need to be addressed to develop the mechanically “soft” materials that will serve functional needs in a fusion pilot plant.

Enhancement of the diffusion bonding process for the development of compact heat exchangers (CHXs) provides an energy efficient solution for high-temperature applications in advanced nuclear reactors and other technologies. However, available information is limited concerning the diffusion bonding (and manufacturing) of CHXs in high temperature applications and associated selection of bonded materials, bonding conditions, mechanical performance, and thermo-fluid characteristics. This article reviews the available knowledge and the ongoing research being conducted to address gaps in information and application.

Moisture-electric energy transformation (MEET) technology is being developed to further expand the utilization of environmental energy sources like thermal power, wind power, hydropower, and solar energy. The goal of the MEET technology is to extract power from environmental moisture with as few conversion processes as possible to satisfy the ever-growing demand for new and more portable energy sources The use of cold spray to produce MEET devices results in a greener process. While the suitability of polyether ether ketone as a MEET material was proven and the deposition of PEEK using cold gas dynamic spray (CGDS) was achieved, additional work is needed to fully characterize the manufacturing of PEEK-based MEET devices via CGDS.

Aircraft engines that minimize fuel consumption and operate on sustainable aviation fuels are key to meeting the air transportation sector’s commitment to net zero CO 2 emissions by 2050. This article reports on work to implement sustainable propulsion technologies, including advanced gas turbine propulsion technologies, engines that are compatible with approved sustainable aviation fuels, hybrid-electric propulsion, and hydrogen propulsion. The article also describes efforts to reduce the environmental footprint related to condensation trails (contrails) from aircraft engine exhaust plumes.

Cobalt alloys are widely used to meet the demanding performance requirements of diesal and natural gas engine valvetrain applications. Alloy J513 alloy was developed to lower costs and provide higher performance while also requiring substantially less cobalt usage.

Multidisciplinary optimization techniques provide a novel method for rapid product development that also meets sustainability goals.

A webinar collaboration between ASM International and the Materials Research Society in 2021 brought together a panel of speakers to discuss the challenges and opportunities on the horizon as electric vehicle designers and manufacturers search for materials with sustainability characteristics.

With the opening of Testbed 80, the largest engine testing facility in the world, Rolls-Royce plans to use its unique capabilities to accelerate the journey toward sustainable aviation technologies supported by the intelligent use of materials.

Energy storage solutions must overcome the challenges of synthesizing and processing dissimilar materials while maintaining high lithium transport through their interfaces.

Increasing use of nonmetallic materials in wind turbine blades is driving the development of nondestructive microwave test methods.

Cold spraying is a potentially attractive method for producing accident tolerant fuel cladding, near-net shape nuclear reactor components, and nuclear fuel storage canisters.

Recent advances in the development of self-healing polymers enhance the longevity of energy harvesting and storage devices.

Use of radiography to inspect insulated generator components without the need to strip insulation offers advantages over other inspection methods to assess serviceability and need for repair. This article outlines some of the considerations involved in using nondestructive radiography techniques to assess component integrity.

Radio frequency inductively coupled plasma (RF-ICP) spraying is shown to be a promising method for producing oxidation-resistant W and W-Cr coatings on plasma-facing surfaces in fission and fusion reactors.

Thermal spray plays an important but latent role in many energy generation applications. Strong R&D commitment is required to further expand its technological envelope. This article addresses future directions in the use of thermal spray coating technologies in the energy sector.

By limiting recombination, passivated emitter and rear cell (PERC) solar cells can provide an absolute efficiency boost of 1%, making their relative efficiency about 7% greater than that of other screen printing methods. This article covers the early stages of the nondestructive and destructive imaging performed to evaluate and enhance the efficiency of PERC solar cells. Electroluminescence images, acoustic images, and scanning electron micrographs were used in this research.

Development of new, radiation-tolerant materials that maintain the structural integrity and safety margins over the course of a nuclear power reactor’s service life requires the ability to predict degradation phenomena. Modern post-irradiation examination methods make use of specialized high-flux test reactors and dedicated characterization facilities to limit occupational exposure and prevent the spread of radioactive contamination. This article illustrates the use of these advanced techniques to characterize precipitates in neutron-irradiated Fe-Cr-Al alloys.