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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Electrodeposited nickel coatings for exceptional corrosion mitigation in industrial grade molten chloride salts for concentrating solar power

Molten chloride salt eutectics are attractive candidates for use as thermal energy storage media and heat transfer fluids in generation-three concentrating solar thermal power (Gen3 CSP) plants. However, corrosion of alloys in molten chloride salts, especially at high temperatures, is an extremely challenging problem that studies focus on lower temperatures, shorter durations, or analytical grade, and high-purity, salts. To date, there has been no study on corrosion or corrosion mitigation in an industrial-grade salt at a high temperature such as 750 °C. To alleviate this knowledge gap, the study presents new multiscale fractal-textured Ni coatings on various alloy surfaces for effective corrosion mitigation at 750 °C in molten chloride salts. Using the electrodeposition method, durable double-layer textured coatings were formed on stainless steel alloys (SS316, SS310, and SS347) and In800H. The corrosion performance of the coatings is investigated in both analytical-grade purity and, for the first time, practically relevant industrial-grade chloride salts. Ni-coated ferrous alloys showed an exceptionally reduced corrosion rate in the range of 350–480 μm/y in analytical-grade salts, and between 450 and 490 μm/y in purified industrial-grade salts at 750 °C. Ni coatings on ferrous alloys reduced corrosion rates by as much as 70% compared to uncoated surfaces and were comparable to the expensive Ha230 alloy with a high Ni content. As a result, by the use of innovative fractal corrosion mitigation coatings, for the first time, low-cost structural alloys are rendered viable for use with industrial-grade chloride salts, which is profoundly beneficial in practical systems.

14 SOLAR ENERGY↗
DOE OSTI2022

Experimental Study of Eutectic Molten Salts NaCl/KCl/ZnCl2 Heat Transfer Inside a Smooth Tube for High-Temperature Application

Abstract Eutectic salts NaCl-KCl-ZnCl2 and NaCl-KCl-MgCl2 are two of the chloride salt systems that are promising for being used as high-temperature heat transfer fluid (HTF) and thermal energy storage (TES) materials in a wide range of temperatures from 230 °C to 750 °C in concentrated solar thermal power systems. To conduct measurement of the heat transfer coefficient of the molten salt at high temperatures, a circulation system and instrumentation of flow and heat transfer was constructed. Experimental measurement of the convective heat transfer coefficients of NaCl-KCl-ZnCl2 (molar fraction: 13.8–41.9–44.3%) inside tubes has been accomplished to find the most suitable heat transfer correlations. Experience of salt processing and operation of the high-temperature heat transfer test system was obtained. Two correlations, Dittus-Boelter equation and Gnielinski’s correlation for Nusselt number against Reynolds number and Prandtl number, are evaluated using the test results, and the latter correlation is recommended due to its better agreement of prediction against tested data.

Energy & Fuels↗
NASA NTRS1991

Constitution of pseudobinary hypoeutectic beta-NiAl + alpha-V alloys

The formation of pseudobinary eutectics between NiAl (beta) and V (alpha) at high temperatures was investigated as a possible way of improving the ductility and toughness of the alloy. It is found that a pseudobinary eutectic, characterized by a large beta+alpha field, is formed in the Ni-Al-V ternary system below about 1370 C. The high-temperature solubility of V in beta is about 14 percent, decreasing markedly with decreasing temperature and increasing Al content above 50 at. pct Al. The pseudobinary hypoeutectic exibits crack resistance under indentation loading.

Cotton, J. D.↗
DOE OSTI2026

Dynamic modeling of heat pipe integrated thermal battery latent heat storage system experiment validation

A heat pipe integrated thermal battery system has been constructed to investigate a high-temperature latent heat thermal energy storage technology that takes advantage of near isothermal operation of latent heat storage and heat pipes to potentially enable high-energy isothermal heat storage. A dynamic model constructed in Modelica has been validated, showing errors between 2.5 °C–39.7 °C across 10-h to 47-h simulations against experiment results, showing good prediction capability of experiment output, especially against phase change time. Model calibrations showing vessel heat-up capability of 3 kW and heat pipes combining to provide 600 W each during experiment operation validate experiment circumstances including reduced material loading and reduced power capability. The experiment configuration uses an Al-Mg-Zn eutectic metal as the storage material, heated via heat tape wrapped around the vessel and guide tubes to bring the system to operation range (>400 °C) and to simulate charging heat exchange, respectively, with heat rejection occurring through the surfaces of the material and facilitated via guide tubes with less insulation wrapping. The model is available in the open-source repository HYBRID on Github.

25 - ENERGY STORAGE↗
NASA NTRS1985

Undercooling and solidification behavior in the InSb-Sb system

Use of the droplet emulsion technique has been successful in studying the undercooling and crystallization behavior of Sb, InSb, and an InSb-Sb eutectic alloy. Both droplet size and imposed cooling rate were influential in controlling the extent of liquid undercooling. The droplet surface coating was of significant importance in determining the resultant solidification product structure through its effect on nucleation kinetics. The maximum undercooling for pure Sb was extended from 0.08 to 0.23 T sub m. While simple crushing techniques provided a dramatic increase in droplet undercooling over the bulk material, emulsification treatments both enhanced this undercooling and allowed successful formation of a metastable simple cubic Sb phase. This phase was stable to temperatures approaching the melting point. The simple cubic phase was detected in droplet samples processed using DTA, air and water quenching, and drop tube processing under a helium gas atmosphere. A deviation in the InSb parent ingot composition limited interpretation of the line compound results, however, emulsification techniques extended the undercooling of this material to 0.17 T sub L and provided a stable, protective surface coating for the droplets. Emulsification of the eutectic alloy was effective at producing various levels of undercooling from 0.1 to 0.2 T sub E. Microstructural examination revealed a normal-type eutectic structure in the undercooled droplets indicating that solidification occurred within the coupled zone and that this zone is somewhat symmetric about the eutectic composition.

Graves, J. A.↗
NASA NTRS2011

Experimental Studies of NaK in a Simulated Space Environment

Space fission power systems are being developed at the National Aeronautics and Space Administration (NASA) and Department of Energy (DOE) with a short term goal of building a full scale, non-nuclear, Technology Demonstration Unit (TDU) test at NASA's Glenn Research Center. Due to the geometric constraints, mass restrictions, and fairly high temperatures associated with space reactors, liquid metals are typically used as the primary coolant. A eutectic mixture of sodium (22 percent) and potassium (78 percent), or NaK, has been chosen as the coolant for the TDU with a total system capacity of approximately 55 L. NaK, like all alkali metals, is very reactive, and warrants certain safety considerations. To adequately examine the risk associated with the personnel, facility, and test hardware during a potential NaK leak in the large scale TDU test, a small scale experiment was performed in which NaK was released in a thermal vacuum chamber under controlled conditions. The study focused on detecting NaK leaks in the vacuum environment as well as the molecular flow of the NaK vapor. This paper reflects the work completed during the NaK experiment and provides results and discussion relative to the findings.

Gibons, Marc↗
NASA NTRS1988

Thermal analysis of heat storage canisters for a solar dynamic, space power system

A thermal analysis was performed of a thermal energy storage canister of a type suggested for use in a solar receiver for an orbiting Brayton cycle power system. Energy storage for the eclipse portion of the cycle is provided by the latent heat of a eutectic mixture of LiF and CaF2 contained in the canister. The chief motivation for the study is the prediction of vapor void effects on temperature profiles and the identification of possible differences between ground test data and projected behavior in microgravity. The first phase of this study is based on a two-dimensional, cylindrical coordinates model using an interim procedure for describing void behavor in 1-g and microgravity. The thermal analysis includes the effects of solidification front behavior, conduction in liquid/solid salt and canister materials, void growth and shrinkage, radiant heat transfer across the void, and convection in the melt due to Marangoni-induced flow and, in 1-g, flow due to density gradients. A number of significant differences between 1-g and o-g behavior were found. This resulted from differences in void location relative to the maximum heat flux and a significantly smaller effective conductance in 0-g due to the absence of gravity-induced convection.

Wichner, R. P.↗
NASA NTRS2008

Formation of gamma(sup prime)-Ni3Al via the Peritectoid Reaction: gamma + beta (+ Al2O3)=gamma(sup prime)(+ Al2O3)

The activities of Al and Ni were measured using multi-cell Knudsen effusion-cell mass spectrometry (multi-cell KEMS), over the composition range 8-32 at.%Al and temperature range T=1400-1750 K in the Ni-Al-O system. These measurements establish that equilibrium solidification of gamma(sup prime)-Ni3Al-containing alloys occurs by the eutectic reaction, L (+ Al2O3)=gamma + Beta(+ Al2O3), at 1640 +/- 1 K and a liquid composition of 24.8 +/- 0.2 at.%al (at an unknown oxygen content). The {gamma + Beta (+Al2O3} phase field is stable over the temperature range 1633-1640 K, and gamma(sup prime)-Ni3Al forms via the peritectoid, gamma + Beta (+ Al2O3)=gamma(sup prime) (+ Al2O3), at 1633 +/- 1 K. This behavior is consistent with the current Ni-Al phase diagram and a new diagram is proposed. This new Ni-Al phase diagram explains a number of unusual steady-state solidification structures reported previously and provides a much simpler reaction scheme in the vicinity of the gamma(sup prime)-Ni2Al phase field.

Copeland, Evan↗
DOE OSTI2022

Gamma Irradiation of NaCl-UCl 3 Salt for the Molten Chloride Fast Reactor

This report documents the results of the gamma ray irradiation of NaCl-UCl 3 eutectic salt in the Advanced Test Reactor (ATR) spent fuel pool gamma tube and subsequent analysis of capsules utilizing the Gas Assay Sample and Recharge (GASR) system. NaCl-UCl 3 salt capsules at four different temperatures, 75C, 150C, 300C and 600C, were irradiated shortly after the core internal changeout (CIC) of the ATR, beginning April 28 th of 2021, and ending on August 18 th of 2021. Re-positioning of the fuel elements in the spent fuel pool to move more fresh fuel elements around the gamma tube occurred on May 11 th of 2021, resulting in an approximate 20% increase in the dose rate and consequently the total absorbed dose. In total, the salt-filled capsules underwent 2638 hours of gamma irradiation from the adjacent freshly discharged ATR spent fuel. Capsule internal pressure measurements were taken via the Gas Assay Sample and Recharge (GASR) system in the INL Hot Fuels Examination Facility (HFEF) following completion of the irradiation. Based on the GASR analysis results, the primary conclusion from this experiment to-date is that radiolytic generation of chlorine gas is insignificant for the dose rates and total absorbed dose that these samples experienced. To elucidate more detailed effects of radiolysis on NaCl-UCl 3 eutectic salts and reach a more definitive conclusion, further advanced analyses such as electron microscopy, simultaneous thermal analysis, and electron paramagnetic resonance are recommended to analyze the capsule wall and salt samples.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1972

Eutectic superalloys strengthened by delta Ni3Cb lamellae, and gamma prime, Ni3Al precipitates.

Bivariant eutectic alloys, located on a liquidus surface within the Ni-Cb-Cr-Al quaternary, were identified which permitted the production of aligned delta Ni3Cb lamellae within a nichrome matrix containing the fcc precipitate gamma prime Ni3Al. The volume fraction of delta and gamma prime could be varied significantly by compositional changes. After directional solidification certain alloys possessed improved ductility and corrosion resistance with respect to the Ni3Al-Ni3Cb eutectic, while their values of tensile and creep strength approached or exceeded those for the Ni3Al-Ni3Cb pseudobinary system. The mechanical properties of the directionally solidified alloy, Ni-19.7 wt % Cb-6.0 wt % Cr-2.5 wt % Al, were evaluated. Its longitudinal strength in tension and creep was found to be superior to all advanced nickel base superalloys. It is thus demonstrated that useful properties for gas turbine airfoil applications can be achieved by reinforcing a strong and tough gamma nichrome matrix containing precipitated gamma prime by a strong lamellar intermetallic compound having greater strength at elevated temperature.

Lemkey, F. D.↗
NASA NTRS1975

Metal matrix composites for aircraft propulsion systems

A report is presented of the current status of development of five materials which might be used in the design of components for advanced aircraft propulsion systems. Boron fiber/aluminum, boron fiber/titanium, and silicon carbide fiber/titanium composites are considered for lightweight compressor fan blades. Directionally solidified eutectic superalloy and tungsten wire/superalloy composites could possibly be used in the design of turbine blades for operational temperatures as high as 1100 C.

Signorelli, R. A.↗
NASA NTRS1981

Fatigue of Ni-Al-Mo aligned eutectics at elevated temperatures

The elevated-temperature mechanical behavior of two aligned eutectics (Ni-8.1 wt % Al-26.4 wt % Mo and Ni-6.3 wt % Al-31.2 wt % Mo) has been investigated utilizing monotonic and cyclic testing in vacuum. Tensile yield strength and fatigue resistance increased from 25 to 725 C, but then were reduced at 825 C. The fatigue lives of specimens tested at 725 C decreased sharply with decreasing frequency. A shift from surface to internal crack initiation was observed upon increasing the test temperature from 725 to 825 C. Stage II crack propagation was observed at both temperatures, in contrast to stage I cracking at 25 C. The test results are compared to those for other nickel and cobalt-base aligned eutectics to show that the frequency effect on fatigue life is not limited to the Ni-Al-Mo system.

Tartaglia, J. M.↗
NASA NTRS1991

Solar dynamic heat receiver technology

A full-size, solar dynamic heat receiver was designed to meet the requirements specified for electrical power modules on the U.S. Space Station, Freedom. The heat receiver supplies thermal energy to power a heat engine in a closed Brayton cycle using a mixture of helium-xenon gas as the working fluid. The electrical power output of the engine, 25 kW, requires a 100 kW thermal input throughout a 90 minute orbit, including when the spacecraft is eclipsed for up to 36 minutes from the sun. The heat receiver employs an integral thermal energy storage system utilizing the latent heat available through the phase change of a high-temperature salt mixture. A near eutectic mixture of lithium fluoride and calcium difluoride is used as the phase change material. The salt is contained within a felt metal matrix which enhances heat transfer and controls the salt void distribution during solidification. Fabrication of the receiver is complete and it was delivered to NASA for verification testing in a simulated low-Earth-orbit environment. This document reviews the receiver design and describes its fabrication history. The major elements required to operate the receiver during testing are also described.

Sedgwick, Leigh M.↗
DOE OSTI2024

SPC-71145 Rev 0 MARVEL Process Heat Extraction System Conceptual Design

The Microreactor Applications Research Validation and Evaluation (MARVEL) reactor will offer experimental capabilities that are not currently available at DOE’s national laboratories. The MARVEL reactor is a microreactor which uses eutectic sodium-potassium alloy (NaK) as a primary coolant. The primary coolant is circulated through four primary loops by natural convection of the coolant. In each loop is a closed well which will accommodate an intermediate heat exchanger (IHX) for extracting heat from the loop. These wells will be referred to in this specification as the “IHX wells”. It is intended for the IHX containment to also be filled with NaK. The MARVEL design team is currently looking for alternative means of extracting heat from these wells to be utilized in downstream applications. This Heat Utilization System (HUS) will enable MARVEL operations including the ability to test, demonstrate, and address issues related to installation, startup, and operations. In addition, it will allow down-stream utilization of process heat for various uses. Depending on the methodology used, the interface between the secondary coolant and the HUS is the Process Heat Extraction System (PHES) and is the subject of this specification.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗
DOE OSTI2024

Real-Time Elemental and Isotopic Measurements of Molten Salt Systems through Laser-Induced Breakdown Spectroscopy

Molten salt reactors are an emerging advanced nuclear reactor concept in which the fuel is dissolved into the working fluid in the form of a high-temperature molten salt. The complex, mobile, and corrosive nature of this fluid presents a fundamental challenge for analytical measurements. Tracking species throughout the reactor is important for ensuring proper operation. This article presents laser-induced breakdown spectroscopy (LIBS) used to monitor the elemental composition of a molten salt and corresponding hydrogen isotopic shifts in real-time. A NaNO 3 –KNO 3 eutectic salt was saturated with protium and deuterium gases, then the effluent aerosol stream formed using an argon sparging vessel was monitored with LIBS. This modular LIBS system permitted several spectrometers to be used simultaneously to capture high-resolution isotopic shifts and provide broadband elemental coverage. Further, the results exhibit how LIBS can be used to understand salt–gas chemical and physical interactions such as diffusion. Furthermore, LIBS’ broad elemental coverage can provide greater insight into the chemical reactions within the salt vessel such as the formation of water vapor by monitoring hydrogen and oxygen signatures simultaneously. Ultimately, this study demonstrates the analytical possibilities of LIBS for real-time monitoring of isotopes and elemental composition in molten salt systems.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1989

Finite element simulations of thermosolutal convection in vertical solidification of binary alloys

Dendritic vertical solidification of a binary alloy is modeled using the finite element method to assess the effect of thermosolutal convection in macrosegregation. The mathematical model assumes steady-state solidification with a planar, undeformable surface defined by the dendrite tips and the eutectic isotherm. The dendritic region is assumed to advance at a constant solidification velocity v. The stability of the modeled system has been investigated and nonlinear calculations performed that show finger-like convection when the system is unstable. Results for lead-tin alloys show that when the system is unstable, convection is only significant in the uppermost part of the mush and is entirely driven by convection in the bulk fluid.

Heinrich, J. C.↗
NASA NTRS1993

Thermal Cycling Fatigue in DIPs Mounted with Eutectic Tin-Lead Solder Joints in Stub and Gullwing Geometries

It has long been known that solder joints under mechanical stress are subject to failure. In early electronic systems, such failures were avoided primarily by avoiding the use of solder as a mechanical structural component. The rule was first to make sound wire connections that did not depend mechanically on solder, and only then to solder them. Careful design and miniaturization in modern electronic systems limits the mechanical stresses exerted on solder joints to values less than their yield points, and these joints have become integral parts of the mechanical structures. Unfortunately, while these joints are strong enough when new, they have proven vulnerable to fatigue failures as they age. Details of the fatigue process are poorly understood, making predictions of expected lifetimes difficult.

fatigue failure solder joints failure mechanisms s↗
NASA NTRS2005

Structures Self-Assembled Through Directional Solidification

Nanotechnology has created a demand for new fabrication methods with an emphasis on simple, low-cost techniques. Directional solidification of eutectics (DSE) is an unconventional approach in comparison to low-temperature biomimetic approaches. A technical challenge for DSE is producing microstructural architectures on the nanometer scale. In both processes, the driving force is the minimization of Gibb's free energy. Selfassembly by biomimetic approaches depends on weak interaction forces between organic molecules to define the architectural structure. The architectural structure for solidification depends on strong chemical bonding between atoms. Constituents partition into atomic-level arrangements at the liquid-solid interface to form polyphase structures, and this atomic-level arrangement at the liquid-solid interface is controlled by atomic diffusion and total undercooling due to composition (diffusion), kinetics, and curvature of the boundary phases. Judicious selection of the materials system and control of the total undercooling are the keys to producing structures on the nanometer scale. The silicon-titanium silicide (Si-TiSi2) eutectic forms a rod structure under isothermal cooling conditions. At the NASA Glenn Research Center, directional solidification was employed along with a thermal gradient to promote uniform rods oriented with the thermal gradient. The preceding photomicrograph shows the typical transverse microstructure of a solidified Si-TiSi2 eutectic composition. The dark and light gray regions are Si and TiSi2, respectively. Preferred rod orientation along the thermal gradient was poor. The ordered TiSi2 rods have a narrow distribution in diameter of 2 to 3 m, as shown. The rod diameter showed a weak dependence on process conditions. Anisotropic etch behavior between different phases provides the opportunity to fabricate structures with high aspect ratios. The photomicrographs show the resulting microstructure after a wet chemical etch and a dry plasma etch. The wet chemical etches the silicon away, exposing the TiSi2 rods, whereas plasma etching preferentially etches the Si-TiSi2 interface to form a crater. The porous architectures are applicable to fabricating microdevices or creating templates for part fabrication. The porous rod structure can serve as a platform for fabricating microplasma devices for propulsion or microheat exchangers and for fabricating microfilters for miniatured chemical reactors. Although more work is required, self-assembly from DSE can have a role in microdevice fabrication.

Dynys, Frederick W.↗