Additive manufacturing allows for the production of complex parts with minimum material waste, offering an effective technique for fabricating permanent magnets which frequently involve critical rare earth elements. In this report, we demonstrate a novel method - Big Area Additive Manufacturing (BAAM) - to fabricate isotropic near-net-shape NdFeB bonded magnets with magnetic and mechanical properties comparable or better than those of traditional injection molded magnets. The starting polymer magnet composite pellets consist of 65 vol% isotropic NdFeB powder and 35 vol% polyamide (Nylon-12). The density of the final BAAM magnet product reached 4.8 g/cm3, and the room temperature magnetic properties are: intrinsic coercivity Hci = 688.4 kA/m, remanence Br = 0.51 T, and energy product (BH)max = 43.49 kJ/m3 (5.47 MGOe). In addition, tensile tests performed on four dog-bone shaped specimens yielded an average ultimate tensile strength of 6.60 MPa and an average failure strain of 4.18%. Scanning electron microscopy images of the fracture surfaces indicate that the failure is primarily related to the debonding of the magnetic particles from the polymer binder. The present method significantly simplifies manufacturing of near-net-shape bonded magnets, enables efficient use of rare earth elements thus contributing towards enriching the supply of critical materials.

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Performance of accident-tolerant fuel and cladding (ATF) candidates must be assessed during the pellet-cladding mechanical interaction (PCMI) phase of a design-basis reactivity-initiated accident (RIA). We describe fiscal year 2019 research activities for the development of separate-effects testing for ATF cladding candidate iron-chromium-aluminum (FeCrAl) tube specimens under loading conditions comparable to PCMI.

Pellet-cladding mechanical interaction (PCMI) is a potential failure mechanism for accident-tolerant fuel (ATF) cladding candidates during a reactivity-initiated accident (RIA). This report summarizes Fiscal Year (FY) 2017 research activities that were undertaken to evaluate the PCMI-like hoop-strain-driven mechanical response of ATF cladding candidates. To achieve various RIA-like conditions, a modified-burst test (MBT) device was developed to produce different mechanical pulses. The calibration of the MBT instrument was accomplished by performing mechanical tests on unirradiated Generation-I iron-chromium-aluminum (FeCrAl) alloy samples. Shakedown tests were also conducted in both FY 2016 and FY 2017 using unirradiated hydrided ZIRLO tube samples. This milestone report focuses on testing of ATF materials, but the benchmark tests with hydrided ZIRLO tube samples are documented in a recent journal article. a For the calibration and benchmark tests, the hoop strain was monitored using strain gauges attached to the sample surface in the hoop direction. A novel digital image correlation (DIC) system composed of a single high-speed camera and an array of six mirrors was developed for the MBT instrument to better resolve the failure behavior of samples and to provide useful data for validation of high-fidelity modeling and simulation tools. The DIC system enable a 360° view of a sample's outer surface. This feature was added to the instrument to determine the precise failure location on a sample's surface for strain predictions. The DIC system was tested on several silicon carbide fiber/silicon carbide matrix (SiC/SiC) composite tube samples at various pressurization rates of the driver tube (which correspond to the strain rates for the samples). The hoop strains for various loading conditions were determined for the SiC/SiC composite tube samples. Future work is planned to enhance understanding of the failure behavior of the ATF cladding candidates of age-hardened FeCrAl alloys and SiC/SiC composites in detail during RIA conditions informed by the computational studies performed under the US Department of Energy Office of Nuclear Energy Advanced Fuels Campaign. The testing instrument and the new DIC system will be further developed to reach different stress-state conditions and to perform tests at elevated temperatures.

New measurements of graphite mode I critical stress intensity factor, K Ic (commonly referred to as the fracture toughness) and the mode II critical shear stress intensity, K IIc , are reported and compared with prior data for K Ic and K IIc. The new data are for graphite grades PCEA, IG-110 and 2114. Variations of K Ic and acoustic emission (AE) data with graphite texture are reported and discussed. The Codes and Standards applications of fracture toughness, K Ic , data are also discussed. A specified minimum value for nuclear graphite K Ic is recommended.

New measurements of graphite mode I critical stress intensity factor, KIc (commonly referred to as the fracture toughness) and the mode II critical shear stress intensity, KIIc, are reported and compared with prior data for KIc and KIIc. The new data are for graphite grades PCEA, IG-110 and 2114. Variations of KIc and acoustic emission (AE) data with graphite texture are reported and discussed. The Codes and Standards applications of fracture toughness, KIc, data are also discussed. A specified minimum value for nuclear graphite KIc is recommended.