Search Results for fusion materials

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.

Ahead of formal certification, many advanced metals have been qualified for 3D printing, allowing for the creation of previously impossible aerospace parts including for the hypersonic environment.

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.

A new fusion cladding process that uses high-intensity arc lamps can produce pinhole free, smooth, uniform coatings as thick as 15 mm from various feedstock materials. This article briefly describes the process and the corrosion, wear, and high-temperature behavior of fusion claddings designed for oil and gas pipelines and related components.

In order to expand the choice of materials available for use in additive manufacturing, parameters that consider welding metallurgy, laser powder interaction, and post processing must be developed. This article describes the outcomes of process development for a steel and stainless steel alloy that are not standard materials for laser powder bed fusion equipment.

The fraction and size of pores present in EBM Ti-6Al-4V specimens varies depending on the melting strategy used, whether linear raster melting or point melting.

An ambitious automotive concept incorporates mixed materials in all major vehicle systems of a five-passenger sedan to achieve an overall weight reduction of 23%. This article explores the vehicle design and material usage details, system by system.

A novel brazing approach for joining SiC-based fuel cladding is a promising technology for enhanced accident-tolerant nuclear fuels.

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.

This article describes how shielding gas composition, either argon or nitrogen, affects the hardness, tensile strength, and toughness of high-power, high-brightness laser welds made on various base materials, including A508 forging steel, 316L stainless steel, Inconel 690, and solution-annealed IN718.

This article discusses the capabilities of fusion or gas-assist fiber laser cutting technology for producing complex shapes from stainless steel, aluminum, nickel, titanium, and other metals ranging in thickness from 0.002 to 0.06 in.

Fabrication of aerospace components using additive manufacturing (AM) has matured to the point where part microstructures and mechanical properties compare well with those of conventionally produced material. This article discusses the basics of AM, part design considerations, CAD models, and build and powder removal considerations.

Metal additive manufacturing has steadily progressed over the past decade, with today’s directed energy deposition processes enabling rapid builds of large structures in near-net shape—and with minimal machining required to achieve final dimensions.

Although the widespread use of titanium alloys is constrained by high costs, powder metallurgy techniques such as additive manufacturing (AM) represent an economical approach to fabricating titanium components. Various approaches to AM, along with examples of components made by different AM processes, are presented. The microstructures and mechanical properties of Ti-6Al-4V produced by AM are also discussed and compared with cast and wrought products. Finally, the economic advantages of AM compared to conventional processing are presented.

Enhanced mining tool performance is achieved through the use of reclaimed NiCrBSi-WC powders in laser metal deposition. Collection, analysis, and reuse of spilled powder lowers production costs and reduces environmental impact.

The extreme high-speed laser application (EHLA) process offers efficient deposition of high-performance materials in aerospace manufacturing, providing key advantages compared to conventional laser cladding. As a sustainable alternative to chrome plating, EHLA excels in material integrity, efficiency, and performance, while reducing costs compared to thermal spray and conventional laser cladding. This article discusses how EHLA can help to address many sustainability concerns within the manufacturing sector.

This article highlights some of the best metallographic practices from a laser powder bed fusion laboratory and provides practical observations of the more universal aspects of powder testing.

The manufacture of electric motors using additive methods offers potential advantages of increased efficiency, weight reduction, and customizability over traditional processes. This article describes some key developments and challenges related to additively manufactured electric motors in terms of manufacturing, materials development, and design.

Metal 3D printing is expanding manufacturing possibilities by enabling new designs and improved outcomes. This article discusses some recent advances in processes and in metals suitable for additive manufacturing.

In Germany, the Federal Institute for Materials Research and Testing (BAM) is addressing challenges in the implementation of additive manufacturing on the industrial landscape for safety-critical applications. This article provides an overview of BAM’s activities in additive manufacturing with a focus on safety (both for applications and the environment) and AM technology innovation for a wide range of materials and manufacturing locations.