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A finite element approach integrated with a novel constitute model to predict phase change, residual stresses and part deformation.

In additive manufacturing, choice of process parameters for a given material and geometry can result in porosities in the build volume, which can result in scrap.

A pressure burst feature has been designed and demonstrated for relieving potentially hazardous excess pressure within irradiation capsules used in the ORNL High Flux Isotope Reactor (HFIR).

This manufacturing method uses multifunctional materials distributed volumetrically to generate a stiffness-based architecture, where continuous surfaces can be created from flat, rapidly produced geometries.

V-Cr-Ti alloys have been proposed as candidate structural materials in fusion reactor blanket concepts with operation temperatures greater than that for reduced activation ferritic martensitic steels (RAFMs).

The lack of real-time insights into how materials evolve during laser powder bed fusion has limited the adoption by inhibiting part qualification.  The developed approach provides key data needed to fabricate born qualified parts.

A novel method that prevents detachment of an optical fiber from a metal/alloy tube and allows strain measurement up to higher temperatures, about 800 C has been developed. Standard commercial adhesives typically only survive up to about 400 C.

Distortion generated during additive manufacturing of metallic components affect the build as well as the baseplate geometries. These distortions are significant enough to disqualify components for functional purposes.

A new nanostructured bainitic steel with accelerated kinetics for bainite formation at 200 C was designed using a coupled CALPHAD, machine learning, and data mining approach.

The microreactor design addresses the need to understand molten salt-assisted electrochemical processes at a controlled scale, enabling real-time observation of structural changes and kinetics.