Publications

Nov, 2025

Journal

Unveiling atomistic mechanisms governing additive manufacturing processability and mechanical behavior of a refractory complex concentrated alloy

Extending the concept of complex concentrated alloys (CCAs) to the refractory alloys (solidus temperature over 2000 °C) space potentially facilitates the design of lightweight structural alloys with service temperatures that exceed those of Ni and Co-based alloys. However, the room and elevated temperature tensile properties of the current refractory-CCAs (R-CCAs) are infe…

Nov, 2025

ORNL Report

Advancing Additive Manufacturing Through Artificial Intelligence–Powered, High-Throughput, Nondestructive Characterization and Process Optimization

Sep, 2025

ORNL Report

Additively Manufactured Pressure Limiting Irradiation Capsule for the High Flux Isotope Reactor

The Advanced Materials and Manufacturing Technologies (AMMT) program previously demonstrated an additively manufactured (AM) irradiation capsule (commonly referred to as a “rabbit”) from 316H stainless steel (SS) for insertion into the High Flux Isotope Reactor (HFIR) at Oak Ridge National Laboratory (ORNL)1. This report details efforts to design and fabricate an AM pressu…

Aug, 2025

ORNL Report

Plasma Facing Component Innovations by Advanced Manufacturing and Design

Jul, 2025

Journal

Design and Demonstration of an Additively Manufactured Integrated Pressure Limiting Structure for Insertion into a Nuclear Research Reactor

An additively manufactured 316L stainless steel pressure limiting structure (PLS) has been designed as an end cap for an irradiation capsule to be inserted into the high flux isotope reactor (HFIR) at Oak Ridge National Laboratory. The PLS was printed using a laser powder bed fusion printer and includes a thin cylindrical rupture wall, a shield, and internal supports to fa…

Jul, 2025

ORNL Report

Design of Novel Hot Gas Component for Gas Turbine Engines Enabled by Materials and Additive Manufacturing Process Development

May, 2025

Journal

Microstructural heterogeneities in additively manufactured refractory alloy C103 and their implications for room and elevated temperature mechanical behavior

Considering the vast component design space enabled by fusion-based additive manufacturing (F-BAM) processes, e.g., directed energy deposition (DED), the scale-up manufacturing of Nb-alloys with F-BAM is advantageous for structural applications. However, varying thermokinetic parameters-induced microstructural heterogeneities are prevalent within the F-BAM processed alloys…

Apr, 2025

ORNL Report

IN-SITU PROCESS MONITORING EVALUATION AND DEMONSTRATION USING ADVANCED CHARACTERIZATION WITH LASER POWDER BED SYSTEMS

Oak Ridge National Laboratory’s (ORNL) Manufacturing Demonstration Facility (MDF) worked with EOS Group to evaluate the current in-situ sensor capabilities of an EOS M290 Laser Powder Bed Fusion machine. The M290 was fitted with a 1 Mega-Pixel (MP) grayscale visible-light camera and a 5 MP temporally integrated (TI) near-infrared (NIR) camera. One print from stainless stee…

Apr, 2025

ORNL Report

Uncertainty Quantification of Fatigue Behavior of Rough AM Surfaces and Microstructures to Enable Hydrogen Gas Turbine

Modification of fossil-fueled industrial gas turbines to accept no/low carbon fuels (Hydrogen, H2/natural gas blends) is a significant undertaking. Successful deployment of this technology sits at the intersection of three design criteria (1) new functional fuel injectors that can burn these fuels, (2) manufacturability to meet cost and time-to-market targets, and (3) dura…

Apr, 2025

ORNL Report

Novel Hot Gas Components for Gas Turbine Engines Enabled by Materials and Additive Manufacturing Process Development

This report covers the activities associated with the development and evaluation of two high-’ superalloys that were designed by external partners on this project, namely Carpenter Technologies Corporation and the University of California-Santa Barbra. One alloy was GammaPrint-700, a cobalt-base superalloy, and the other a nickel-base (Ni-base) superalloy GammaPrint-1100.…

Nov, 2024

Journal

Integrated Top-Down Process and Voxel-Based Microstructure Modeling for Ti-6Al-4V in Laser Wire Direct Energy Deposition Process

Laser-wire metal additive manufacturing (AM) is one of the ideal direct energy deposition (DED) processes for creating large-scale parts with a medium level of complexity. However, the DED process involves complex thermal signatures and wide length scales making the fabrication of realistic AM components and part qualification often reliant on experimental trial-and-error…

Mar, 2024

ORNL Report

RAPID ALLOY SELECTION AND ADDITIVE MANUFACTURING OF NICKEL-BASED SUPERALLOYS