High plasticity in refractory composite fabrication by ultrasonic additive manufacturing

Hyer, Holden C.; Massey, Caleb P.; Chappell, Jonathan; Garrison, Ben; Parish, Chad; Seibert, Rachel; Smith, Kurt; Nelson, Andrew

doi:10.1016/j.compositesb.2024.112051

Title: High plasticity in refractory composite fabrication by ultrasonic additive manufacturing

Journal Article · 05 December 2024 · Composites. Part B, Engineering

DOI: https://doi.org/10.1016/j.compositesb.2024.112051 · OSTI ID:2481221

^[1]; Massey, Caleb P. ^[1];

^[1];

^[1]; Seibert, Rachel ^[1]; Smith, Kurt ^[1];

^[1]

Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Refractory metal composites are desirable for use in extreme environments that require materials with high specific strengths and resilience to external environments such as that found in nuclear and aerospace. However, due to the high melting temperature of refractories, liquid state joining processes such as welding remains difficult. Ultrasonic additive manufacturing (UAM) provides a potential route for processing refractory composites because it is a solid-state (i.e., no-melting) process and allows for intermittent machining operations to be performed between welds. Further, to demonstrate refractory composite fabrication, this study utilized UAM to machine a cavity to locate and sequester a Mo foil in a Zircaloy-4 (Zry-4) baseplate and additively build over the top with Zry-4 foils, thereby embedding the Mo in Zry-4 matrix. Significant deformation of the Zry-4 microstructure was observed: this deformation caused adiabatic heating and subsequent dynamic recrystallization through the transformation from α→β and then back to α as the material cooled. Flexural testing of the Zr–Mo composite revealed no delamination or failure, but the strength was not as expected, falling lower than a cold-worked Zry-4 sample. Finite element analysis supported that some bonding must have existed between the Zry-4 and Mo. There was indeed an interdiffusion zone at the Zry-4 foil–Mo foil interface, observing a metastable body-centered cubic β-Zr lathe. It was determined that sufficient strain energy was present to encourage the nucleation of the β-Zr grain along α-Zr grains. Future work is warranted to investigate UAM for refractory composite fabrication.

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Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOE National Nuclear Security Administration (NNSA)

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 2481221

Journal Information:: Composites. Part B, Engineering, Journal Name: Composites. Part B, Engineering Vol. 292; ISSN 1359-8368

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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