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ANL-ART-142

Report on the completion of the development of processing map from as-cast Alloy 709 materials

Applied Materials Division

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ANL-ART-142

Report on the completion of the development of processing map from as-cast Alloy 709 materials

prepared by M. C. Messner, X. Zhang, and T.-L. Sham Applied Materials Division, Argonne National Laboratory

August 2018

Abstract

This report provides details on the completion of the development of the processing map from the as-cast Alloy 709 materials. The report is a Level 4 deliverable in FY18 (M4NT- 18AN050502012), under the Work Package NT-18AN05050201, “A709 Development” performed by Argonne National Laboratory, as part of Advanced Structural Materials Program for the Advanced Reactor Technologies (ART).

The report describes the development of a processing map to guide the development of hot work regimens for A709. The maps combine high-temperature flow stress measurements, described in a companion report by Oak Ridge National Laboratory, and metallographic observations, described here, into a single diagram that can be used to select hot working parameters to avoid regions of plastic instability and to avoid the development of unfavorable microstructures. This report describes the process of creating the map, provides the final map for A709, and uses the processing map to describe two potential hot work regimens that could be used in processing a DOE round ingot into bar stock.

Table of Contents

Abstract ...... iii Table of Contents ...... v List of Figures ...... vii List of Tables ...... ix 1. Introduction ...... 1 2. Microstructural Characterization ...... 5 3. Creating Processing Maps ...... 11 4. Discussion ...... 15 5. Conclusions ...... 16 Acknowledgements ...... 17 References ...... 19 Distribution List ...... 20

List of Figures

Figure 1-1. a) Metallographic photo showing a crack originated from the surface of an A709 plate. b) EDS spectrum of chromium-rich oxide found in a crack ...... 3 Figure 2-1. a) Sectioning of the compression-tested samples at mid-plane. b) Polished samples ready for metallography...... 5 Figure 2-2. Grain structure of the as-cast AOD slab...... 6 Figure 2-3. Metallography of two samples showing dynamic recrystallization (nucleation stage)...... 6 Figure 2-4. Metallography of two samples showing flow instability, manifested by adiabatic heating band and flow localization...... 7 Figure 2-5. Metallography of two samples showing cracks/voids along grain boundaries, and occasionally within grain interior...... 7 Figure 2-6. Microstructural mechanisms of samples deformed at different temperature/strain rate combination...... 8 Figure 3-1. Processing maps at a) 0.1, b) 0.3, and c) 0.5 true strain ...... 13

List of Tables

Table 1-1. Chemical composition of melt of Alloy 709 heat # 58776 (in wt%)...... 2 Table 2-1: Tabulated summary of metallographic observations...... 9

Report on the completion of the development of processing map from as-cast Alloy 709 materials August 2018

1. Introduction

Advanced materials are a key element in the development of new nuclear energy systems. High- performance structural materials allow for a compact and simple design of the reactor structure and have the potential to reduce the construction and operational costs for next-generation advanced nuclear reactors. Due to the significant enhancement in time-dependent mechanical properties of the austenitic stainless steel Alloy 709 relative to 316H stainless steel, a reference construction material for SFR systems, code qualification of Alloy 709 was recommended. A comprehensive plan for the development of a 500,000-hour, 760C ASME Code Case and the resolution of licensing issues for Alloy 709 was developed in FY15. A Phase I implementation of this plan that includes a 100,000-hour, 650°C ASME code case and the initiation of very long term creep tests, thermal aging, and sodium exposure of Alloy 709 was established. The maximum use temperature of the 100,000-hour ASME code case has been increased to 760°C to support possible applications in Fluoride salt-cooled High-temperature Reactors (FHRs).

Alloy 709 is derived from NF709 (Fe-20Cr-25Ni-1.5Mo-Nb,B,N), which was a commercial heat- and corrosion- resistant austenitic stainless steel developed by Nippon Steel Corporation in Japan for boiler tubing applications. The high strength of NF709 is achieved by controlling the carbon content to 0.07–0.10% and precipitation strengthening by NbC and CrNbN (Z phase). NF709 also shows good fabricability properties and weldability. It is regarded as one of the best austenitic steels for elevated temperature applications among commercially-available austenitic alloy classes. The NF709 alloy provides time dependent strength nearly double that for conventional 304 and 316 stainless steels at sodium-cooled fast reactor relevant temperatures (Busby et al 2008). While the cost for this alloy has been estimated at approximately 2-4 times that for 304 SS (and 1.5 to 3 times that for 316 SS), many fossil plants have found that the improved performance outweighs the commodity cost, and is still far below the cost for Ni-based superalloys at comparable strengths. Alloy 709 has the same chemical composition as NF709 but is intended for sodium fast reactor applications that include reactor vessel, core supports, primary and secondary piping, and possibly intermediate heat exchanger and compact heat exchanger. Hence development of processing conditions and fabrication scale up for different product forms such as plates, pipes, bars, forgings and sheets, in addition to seamless tubing, are required.

One of the major concerns in applications of the advanced alloys in sodium-cooled fast reactors is their long-term microstructural stability and associated degradation of mechanical properties during service. Previous work (Li, et al. 2010–2013) has showed that tensile properties of these advanced materials degrade with time, when exposed to high temperatures and liquid sodium. Significant microstructural changes during prolonged thermal and sodium exposures can lead to dramatically different responses to service environments.

In FY17 fabrication scale-up effort, began in FY16, was completed for Alloy 709. The effort culminated in the procurement of four ingots (heat 58776), totaling about 45,000 lb, that were bottom-poured from the melt by a commercial vendor in September 2016. The chemistry aims and the actual melt compositions are also shown in Table 1-1. The master melt produced the following ingots: 1. one (1) AOD slab, approximately 13”x42” cross-section

ANL-ART-142 1 Report on the completion of the development of processing map from as-cast Alloy 709 materials August 2018

2. one (1) ESR slab, approximately 12”x42” cross-section 3. two (2) ESR round ingots, 20” diameter The ESR slab was sectioned into two-halves. One of the halves was homogenized at 2192°F (1200°C) for 48 hours and water quenched, denoted as the ESR-homogenized slab. One of the ESR 20” diameter ingot was homogenized at 2192°F (1200°C) for 48 hours and water quenched, denoted as the ESR-homogenized round ingot.

The slabs were rolled into plates and solution-annealed at three different temperatures: 1050°C, 1100°C and 1150°C. The plates were subsequently distributed to ANL, ORNL and INL for supporting the Alloy 709 Code Case development, for fabrication of weldments, and for NEUP projects. Samples from the as-rolled plates and the annealed plates were cut and analyzed to determine their microstructures, hardness values, grain sizes, and tensile properties. The results showed that the scaled up heat of Alloy 709 fabricated using commercial practice exhibited tensile properties that exceeded the minimum values specified in the ASME Code Case for commercial heats of Alloy 709 (Natesan, et al. 2017).

Table 1-1. Chemical composition of melt of Alloy 709 heat # 58776 (in wt%). Alloy 709 C Cr Ni Mn Mo N Si P Ti Nb B Fe

Specificati 0.04- 19.5- 23-26 1.5 1.0- 0.14- 1.0 <0.025 0.2 0.1- 0.002- Bal on range 0.10 23 2.0 0.16 0.4 0.01

Aim 0.07 20 25 0.9 1.5 0.15 0.40 * 0.05 0.25 0.002- Bal 0.005

Actual 0.066 19.93 24.98 0.91 1.51 0.148 0.44 0.014 0.04 0.26 0.0045 Bal

*The P shall not exceed 0.025 wt%.

It was observed that one of the hot-rolled plates (heat 58776-3RAA1, corresponding to ESR- homogenized with 1050°C annealing) had surface cracks. The material was studied by an independent laboratory and showed that the cracks are associated with high temperature scale and stringers of chromium-rich oxides (Figure 1-1). It was suspected that they were caused by incorrect hot-working conditions (i.e. temperature/strain rate combinations) during the last few passes of the rolling process.

A processing map for the as-cast Alloy 709 material will aid in determining an optimized process for working the 20” round ingot(s) into bars. A processing map is an explicit representation of the response of a material, in terms of microstructural mechanisms, to the imposed process parameters and consist of a superimposition of a power dissipation and an instability map (Prasad, et al., 2015). The input to generate a processing map is the experimental data of flow stress as a function of temperature strain rate and strain. Those data can be obtained from compression tests. In FY18, hot compression tests on cylindrical, as-cast A709 samples (heat 58776) were performed by ORNL (Wang, et al., 2018). The test data and the samples were sent over to ANL for generating the processing map.

2 ANL-ART-142 Report on the completion of the development of processing map from as-cast Alloy 709 materials August 2018

The objective of this project is to develop the processing map for the as-cast Alloy 709 material (heat 58776). Compression test data was processed to generate the dissipation and instability maps. Microstructural characterization of the as-cast and the deformed samples was performed to determine the hot deformation mechanisms. This report describes the process of generating these data and combining them into a processing map for A709.

Figure 1-1. a) Metallographic photo showing a crack originated from the surface of an A709 plate. b) EDS spectrum of chromium-rich oxide found in a crack

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Report on the completion of the development of processing map from as-cast Alloy 709 materials August 2018

2. Microstructural Characterization

2.1. Sample Preparation

Three as-cast samples (from the AOD slab) and 45 hot compression-tested samples (Wang, Zhang, and Feng, 2018) were received at ANL from ORNL between May and July 2018. The samples were deformed at different temperature/strain rate combinations to approximately 50% engineering strain. The samples were irregularly shaped, unlike the conventionally barreled shape for cylindrical samples after compression, due to the mm-sized as-cast grains which caused non-uniform plastic flow. The samples were sectioned at mid-plane using the electrical discharge machining (EDM), as shown in Figure 2-1 (a). The samples were polished to a metallography finish and etched using a chemical reagent (30 mL HCl, 30 mL distilled water, and 10 mL HNO3). Figure 2-1(b) shows a photo of the samples ready for optical metallography.

Figure 2-1. a) Sectioning of the compression-tested samples at mid-plane. b) Polished samples ready for metallography.

2.2. Microstructural characterization

2.2.1. As-cast microstructure

The microstructure of the as-cast Alloy 709 is shown in Figure 2-2. Grain boundaries and microscale segregations due to solidification are visible. The grain sizes are very large, on the order of millimeters.

2.2.2. Microstructure after hot compression tests

Optical metallography was performed around the center of the mid-plane for each compression- tested sample. The following microstructural processes have been observed at different temperature/strain rate combinations: dynamic recrystallization (partial, at nucleation stage), flow instability, and void/crack formation. Figure 2-3, Figure 2-4, and Figure 2-5 are representative micrographs of each microstructure on selected samples.

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Figure 2-6 summarizes the microstructural observations as a function of temperature and strain rate. The microstructural mechanisms of flow instability and void/crack are undesired in materials processing, while recrystallization is desired. Table 2-1 records the microstructural feature observed in each sample.

Figure 2-2. Grain structure of the as-cast AOD slab.

Figure 2-3. Metallography of two samples showing dynamic recrystallization (nucleation stage).

6 ANL-ART-142 Report on the completion of the development of processing map from as-cast Alloy 709 materials August 2018

Figure 2-4. Metallography of two samples showing flow instability, manifested by adiabatic heating band and flow localization.

Figure 2-5. Metallography of two samples showing cracks/voids along grain boundaries, and occasionally within grain interior.

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Figure 2-6. Microstructural mechanisms of samples deformed at different temperature/strain rate combination.

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Table 2-1: Tabulated summary of metallographic observations.

Sample ID Nominal Average strain Observed feature temperature (ºC) rate (s-1) G101 900 1.25e-2 Partial recrystallization G106 900 1.03e-1 Flow instability G107 900 3.14e+1 Voids and cracking G108 1000 1.13e-3 Voids and cracking G110 1150 1.72e-1 Partial recrystallization G111 900 1.32e+0 Voids and cracking G201 1200 8.78e-2 Partial recrystallization G202 1200 3.53e+1 Unclear G203 1100 1.14e-3 Unclear G205 950 2.87e+1 Voids and cracking G206 900 3.68e+0 Flow instability G208 1050 2.92e+1 Voids and cracking G211 1050 7.42e-1 Partial recrystallization G301 1125 1.30e+0 Partial recrystallization G302 950 1.23e-3 Partial recrystallization G305 950 1.16e-1 Voids and cracking G310 1100 1.16e-2 Partial recrystallization G401 1100 8.00e-1 Partial recrystallization G403 1100 9.96e-2 Partial recrystallization G409 1000 3.27e+1 Unclear G601 950 1.34e-2 Partial recrystallization G603 1150 1.79e+1 Partial recrystallization G605 1150 1.50e-3 Unclear G608 1150 1.36e-2 Partial recrystallization G611/G809 900 1.10e-3 Voids and cracking G701 1050 1.50e-3 Partial recrystallization G702 1100 3.46e+1 Partial recrystallization G707 1200 1.32e+0 Partial recrystallization G709 1150 7.66e-1 Partial recrystallization G710 1200 1.09e-3 Partial recrystallization G711 950 8.78e+0 Voids and cracking G808 1200 4.50e+0 Partial recrystallization G901 1200 1.16e-2 Partial recrystallization G904 1100 4.57e+0 Partial recrystallization G905 950 1.42e+0 Partial recrystallization G909 1000 1.21e-1 Partial recrystallization G910 1000 4.43e+0 Flow instability G911 1150 2.84e+1 Voids and cracking

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Report on the completion of the development of processing map from as-cast Alloy 709 materials August 2018

3. Creating Processing Maps

A processing map collects information on power dissipation efficiency, plastic instability, and microstructure evolution into a single diagram designed to aid the selection of hot working parameters to achieve optimal final material properties (Prasad, et al., 2015). Two types of experimental data are required to generate a complete map for a given material: compression flow curves covering a grid of (temperature, strain rate) points in the processing region of interest and corresponding post-test metallography indicating the microstructural consequences of the compressive strain on the initial, as-cast material. The microstructural observations collated into the maps developed here are summarized in the previous chapter. A companion report describes the process of generating the experimental flow curves using a Gleeble® thermal-mechanical testing machine (Wang, et al., 2018).

Power dissipation efficiency can be interpreted as a measure of the efficiency of hot work. A higher dissipation efficiency indicates more of the power input to the hot working process is being converted into microstructural change. As the goal of the hot work process is to recrystallize the initial cast microstructure into a more favorable wrought grain structure, ideally the process parameters should be calibrated so that most of the hot work occurs in the high- efficiency regime.

To determine the dissipation efficiency from the experimental flow curve data it must be cast into a model for the material flow stress as a function of temperature and strain rate. The classical model is power law rate sensitivity = ( , , ) ( , , ) where is the flow stress, and are parameters that𝑚𝑚 𝑇𝑇 depend𝜀𝜀 𝜀𝜀̇ on temperature, strain, and strain 𝑓𝑓 rate, and is the strain rate. In this mo𝜎𝜎 del 𝐴𝐴 𝑇𝑇is 𝜀𝜀the𝜀𝜀̇ rate𝜀𝜀̇ sensitivity exponent. Given a calibration 𝑓𝑓 of ( 𝜎𝜎, , ) to experimental𝐴𝐴 data,𝑚𝑚 the power dissipation efficiency is 𝜀𝜀̇ 𝑚𝑚 2 = . 𝑚𝑚 𝑇𝑇 𝜀𝜀 𝜀𝜀̇ + 1 𝑚𝑚 Unstable plastic flow results in flow localization𝜂𝜂 and the development of microstructural defects like voids, cracks, and adiabatic slip bands, 𝑚𝑚which will persist through subsequent solution annealing into the final material. A hot working regimen should be selected that avoids creating these unfavorable features by avoiding unstable plastic flow. Given a model for rate sensitivity and assuming the classical power law model, stable plastic flow is the deformation regime where ln + 1 = + > 0. ln(𝑚𝑚) 𝜕𝜕 � � The parameters and depend𝜉𝜉 on the 𝑚𝑚temperature,𝑚𝑚 strain rate, and amount of strain. Conventionally, processing maps are made𝜕𝜕 at fixed𝜀𝜀̇ strain and so they can be plotted as contours of dissipation efficiency𝜂𝜂 and𝜉𝜉 a region of unstable plastic flow as functions of strain rate and temperature.

To compute these quantities at various levels of strain, first the flow stress at the strain of interest was extracted from the experimental compression curves. Many of the curves for high strain rate deformation showed ringing behavior, as the test captured discrete stress waves moving through the samples. This happens when the rate of deformation exceeds the time required for stress

ANL-ART-142 11 Report on the completion of the development of processing map from as-cast Alloy 709 materials August 2018 waves to propagate through the sample gauge and keep the specimen at an approximate quasi- static equilibrium. Essentially, the test is capturing discrete shock propagation and reflection in the sample. The experimental curves were first smoothed by fitting a univariate spline to the data to produce a relation for the flow stress as a function of strain. This function was then averaged over a window of 5% true strain to calculate the flow stress at the strain of interest. This process was repeated for all the experimental flow curves to create a database of the flow stress, at fixed strain as a function of strain rate and temperature. The actual, average measured strain rate over the test was used in constructing this database.

The rate sensitivity exponent can be computed by taking the derivative ln = . ln 𝑓𝑓 Numerically, this derivative was computed by𝜕𝜕 fitting𝜎𝜎 a cubic polynomial to the experimental 𝑚𝑚 flow stress data at each, fixed test temperature.𝜕𝜕 This𝜀𝜀 ̇ model for the flow stress as a function of strain rate could then be differentiated to obtain the rate sensitivity exponent. Repeating this process for each test temperature builds a database mapping the temperature and strain rate to the rate sensitivity exponent. This database can be used directly to compute the power dissipation efficiency. Finally, to compute the flow stability criterion the rate sensitivity data was re- interpolated with a cubic polynomial and the derivative expression for computed using the equation above. 𝜉𝜉 This process was repeated for 0.1, 0.3, and 0.5 true strain. The corresponding processing maps plot contours of the dissipation efficiency, as a % efficiency, and the region of unstable flow, which is the zero contour of . The maps plot the metallography results, described in the previous chapter, on top of this information extracted from the experimental flow curves. For each sample, a favorable microstructure𝜉𝜉 was given a value of 1 and an unfavorable microstructure given a value of 0. The final processing maps plot the 0.5 contour of this indicator as a function of temperature and strain rate.

Figure 3-1 shows the three processing maps for A709 for 0.1, 0.3, and 0.5 true strain. The dissipation efficiency changes only slightly between the three different strain levels. The region of unstable flow changes as the strain in the samples increases. However, it essentially covers the same region of hot working parameters, extending from high to low strain rates in between 900º and 1050º C. The microstructural observations approximately align with the region of unstable plastic flow, again indicating an unfavorable processing regime in the low temperature, high strain rate part of the processing phase space.

12 ANL-ART-142 Report on the completion of the development of processing map from as-cast Alloy 709 materials August 2018

a) b)

c)

Figure 3-1. Processing maps at a) 0.1, b) 0.3, and c) 0.5 true strain

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Report on the completion of the development of processing map from as-cast Alloy 709 materials August 2018

4. Discussion

These processing maps are intended to guide the hot working of the DOE round ingot into bar product as well as to provide a reference for processing future heats of A709. While the final processing maps (Figure 3-1) do show some variation with the amount of prior strain, the general trend is that hot work at temperatures less than 1000º C at low strain rates or 1050º C at fast strain rates produce plastic instability in the material and correspondingly result in unfavorable microstructures. Future hot working regimens should avoid low temperature processing by either reheating the billet in between forming operations or by using the adiabatic heating generated by higher strain rate processing to maintain the billet temperature. The latter method may require additional modeling of the forming process in order to achieve the right amount of adiabatic heating without deforming the billet too fast and potential entering the region of instability shown in the processing maps at fast strain rates.

Some variation in the processing maps with the accumulation of strain should be expected as microstructural changes affect the material rate sensitivity. Hot work regimens should be based on the general form of the processing diagram, rather than on a specific diagram for a particular level of strain.

Though not shown in the processing maps, the metallography shows that at very fast strain rates the material develops an unfavorable microstructure at all temperatures (Table 2-1). Processing at true strain rates greater than 101 s-1 should be avoided. Additionally, grain growth in austenitic stainless steels occurs very quickly above 1250º C. To achieve a reasonably fine-grained microstructure all hot work should take place below this temperature.

The energy dissipation contours on Figure 3-1 show that hot work is most efficient at low strain rates and around 1150º C. Ideally, hot working should be done in these conditions to minimize the amount of rolling energy, time, and deformation required to achieve the desired microstructure. This may require heating the billet in between forming operations. Alternatively, the material could be heated to close to 1250º C and increasingly faster forming operations applied to maintain the billet temperature through adiabatic heating. However, such a processing strategy must also limit the maximum strain rate to less than 101 s-1 to avoid the high- rate region of instability.

The samples studied in this project were water quenched immediately following the hot compression tests to preserve the microstructure generated during deformation. This may be a different condition from the actual hot working in mills, where materials are left air-cooled. As a result, microstructures can be different. For example, the recrystallization in the samples studied here is always in the nucleation stage, but in the materials from the mills it can be more complete. Nevertheless, the microstructural mechanisms from hot working will not change.

ANL-ART-142 15 Report on the completion of the development of processing map from as-cast Alloy 709 materials August 2018

5. Conclusions

This report provides details on the completion of the development of processing map from as- cast Alloy 709 materials. The report is a Level 4 deliverable in FY18 (M4NT- 18AN050502012), under the Work Package NT-18AN05050201, “A709 development” performed by Argonne National Laboratory, as part of Advanced Structural Materials Program for the Advanced Reactor Technologies (ART).

Processing maps have been created to guide the hot work of A709. These diagrams combine information from high-temperature flow stress measurements, conducted at Oak Ridge National Laboratory and described in a companion report, and metallography, described in this report, to create a series of processing maps at several levels of deformation. These maps can be used to determine hot working regimens for the existing DOE round ingot and future heats of A709 material. This report describes two potential processing programs, based on the processing maps, which might be used for the DOE ingot. Final determination of a hot working schedule will require coordinating with the processing vendor and will depend on the vendor’s capability to either reheat the billet or control the hot working strain rate.

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Acknowledgements

This research was sponsored by the U.S. Department of Energy (DOE) under Contract DE- AC02-06CH11357 with the Argonne National Laboratory (ANL), managed and operated by UChicago Argonne LLC. Programmatic direction was provided by the Office of Advanced Reactor Technologies (ART) of the Office of Nuclear Energy (NE).

The authors gratefully acknowledge the support provided by Alice Caponiti, Director, Office of Advanced Reactor Technologies, Sue Lesica, Federal Manager, ART Advanced Materials Program, and Robert Hill of ANL, National Technical Director, ART Fast Reactors Campaign.

We gratefully acknowledge the support provided by Yanli Wang at Oak Ridge National Laboratory and Richard N. Wright from Idaho National Laboratory and thank David Rink of ANL for assisting in metallography.

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Report on the completion of the development of processing map from as-cast Alloy 709 materials August 2018

References

Busby, J. T., S. Byun, R. Klueh, P. Maziasz, and J. Vitek, K. Natesan, M. Li, R. Wright, S. Maloy, M. Toloczko, A. Motta, B. D. Wirth, G. R. Odette, and T. Allen, “Candidate Developmental Alloys for Improved Structural Materials for Advanced Fast Reactors,” ORNL/GNEP/LTR-2008-023, March 2008. Li, M, Argonne National Laboratory, unpublished information, 2013. Li, M., Argonne National Laboratory, unpublished information, 2011. Li, M., Argonne National Laboratory, unpublished information, 2010. Natesan, K., Zhang, X., Sham, T.-L., and Wang H., “Report on the completion of the procurement of the first heat of Alloy 709”, ANL-ART-89, June 2017. Prasad, Y. V. R. K., Rao, K. P., and Sasidhara, eds. “Hot Working Guide – A Compendium of Processing Maps”, 2nd ed. ASM International, 2015. Wang, Yanli, Suhong, Zhang, and Freng, Zhili. “Gleeble Compression Tests on As-cast Alloy 709 Samples.” ORNL/TM-2018/932, 2018.

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Distribution List

Name Affiliation Email Caponiti, A. DOE [email protected] Gouger, H.D. INL [email protected] Grandy, C. ANL [email protected] Hill, R.N. ANL [email protected] Krumdick, G.K. ANL [email protected] Lesica, S. DOE [email protected] Li, M. ANL [email protected] McMurtrey, M INL [email protected] Messner, M.C. ANL [email protected] Natesan, K. ANL [email protected] Qualls, A.L. ORNL [email protected] Sham, T.-L. ANL [email protected] Singh, D. ANL [email protected] Sowinski, T.E. DOE [email protected] Wang, H. ORNL [email protected] Wang, Y. ORNL [email protected] Wright, R. INL [email protected] Zhang, X. ANL [email protected]

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August 2018

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