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DOE OSTI2024

Robust Solar Receivers Using MAX Phase Materials

This work was supported by the U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy under the Solar Energy Technologies Office Award Number 35928. The objective of the proposed effort was to develop and optimize additive manufacturing technologies for low-cost fabrication of high-temperature receivers using MAX phase-based materials (Ti 3 SiC 2 and Ti 3 AlC 2 ). MAX phase materials are a group of ternary metal carbides and nitrides where M stands for an early transition metal element, A is a group 13–16 element, and X is C and/or N. In Phase 1, the binder jetting additive manufacturing process was used to synthesize and characterize the Ti 3 SiC 2 MAX phase material. The typical process involved first producing a TiC preform using binder jetting followed by infiltration of the preform with silicon melt to form Ti 3 SiC 2 in situ. The reaction-infiltrated samples showed formation of MAX phase in the sample core; however, the surface showed cracking. Various process conditions—cooling rates, hold times, Si proportion, etc.—were varied to minimize the surface cracking. The fabricated MAX phase core was characterized by microstructure analysis and evaluations of mechanical properties such as hardness and thermal shock. In Phase 2, the focus included fabrication of Ti 3 SiC 2 MAX phase materials by spark plasma sintering (SPS) and synthesis of Ti 3 AlC 2 MAX phase materials by the Al melt infiltration process. It is expected that Al infiltration will not cause sample cracking, since Al does not expand during solidification. In addition, other processing approaches were investigated to fabricate the MAX phase materials, such as SPS with a graphite bedding approach for producing short-length Ti 3 AlC 2 MAX phase tubes for demonstration of prototypical Concentrating Solar Power receiver tubes. Fabricated samples underwent thermo-mechanical testing to validate the materials for the solar receiver application at temperatures >1000°C. In Phase 3, the effort focused on the development and optimization of the Ti-Al-C MAX phase composite material using the Al melt infiltration approach. We started with optimization of precursor powders and making preform structures by either pressing them in a die or using the binder jetting additive manufacturing process followed by Al melt infiltration. In addition, we investigated the formation of preform structures by cold isostatic pressing followed by Al melt infiltration for making Ti-Al-C MAX phase composite. Thermo-mechanical characterizations, such as creep, strength, and thermal shock, were conducted to establish the structures’ performance.

36 MATERIALS SCIENCE↗

DOE OSTI2020

FINAL TECHNICAL AND ECONOMIC FEASIBILITY STUDY ON THE APPLICATION OF A HEAT INTEGRATED POST-COMBUSTION CO2 CAPTURE SYSTEM WITH HITACHI ADVANCED SOLVENT INTO EXISTING COAL-FIRED POWER PLANT

This report contains the results of a techno-economic assessment (TEA) conducted of a heat integrated post-combustion CO2 capture process with Hitachi advanced solvent for retrofit into an existing coal-fired power plant (but treated as greenfield plant on cost analysis). The process has been developed by the University of Kentucky Center for Applied Energy (UK CAER). EPRI was chiefly responsible for this analysis, with significant input from WorleyParsons, Hitachi Power Systems America (Hitachi) and UK CAER. The project also involves the design, fabrication, installation, testing, and analyses of a slipstream facility located at L&GE-KU’s E.W. Brown Generating Station to demonstrate the UK CAER carbon capture system that could utilize heat integration with the main power plant. The design, start-up, and baseline of the pilot system was performed with a generic 30 wt% MEA solvent to obtain data for direct comparison with the DOE/NETL Reference Case followed by testing Hitachi’s proprietary solvent H3-1. In this techno-economic analysis, two cases utilizing the UK CAER process are compared, using different approach temperatures and solvent, against the DOE/NETL Reference Case (Case 10). The results are shown comparing the energy demand for post-combustion CO2 capture and the net higher heating value (HHV) efficiency of the power plant integrated with the post-combustion capture (PCC) plant. A levelized cost of electricity (LCOE) assessment was performed showing the costs of the options presented in the study. The key factors contributing to the reduction of LCOE were identified as CO2 partial pressure increase at the flue gas inlet, thermal integration of the process, and performance of the Hitachi H3-1 solvent. Recent UK CAER process pilot-scale testing data and process simualtion data showed that the packing heights of absorber and stripper columns were significantly oversized in the prelimanary TEA (Task 2 of this project) and thus updated in this final TEA for the H3-1 case only. In addition, the solvent make-up cost for H3-1 was updated based on lattest test results. Finally, a heat integration with the main power plant was applied in this final TEA to increase overall energy effciency for both the MEA and H3-1 cases. Additonal reductions in capital and operational costs are expected but not taken into account here. Shorter columns result in reduced pressure drops, smaller blower head and pump hydraulic head requirements. An increase in overall energy efficiency resuls in a decreased size of the power plant, the CCS and a reduced parasitic steam requirement to the CCS. The net efficiency of the UK CAER integrated PC power plant with CO2 capture changes from 26.2% for the Reference Case 10 plant in 2010 revised DOE/NETL baseline report to 27.6% for the MEA options considered, and 29.1% for the options utilizing the Hitachi advanced solvent. The UK CAER Process + Hitachi case also produces an extra 30.9 MW of generation compared to the UK CAER Process + MEA case and total 60.9 MW more than DOE Case 10. LCOE ($/MWh) values are $172.08/MWh for the MEA option and $157.65/MWh for the Hitachi H3-1 solvent cases considered in comparison to $189.59/MWh in January 2012 dollar for the Reference Case 10. The UK CAER CCS process with MEA case lowers energy consumption for CO2 capture to 1340 Btu/lb-CO2 captured as compared to 1540 Btu/lb-CO2 in the Reference Case 10. The UK CAER CCS process with H3-1 case further lowers energy consumption for CO2 capture to 973 Btu/lb-CO2 captured, for an advantage of 36.8% less energy consumption than Case 10. The study also shows 38.1% less heat rejection associated with the carbon capture system from 3398 MBtu/hr (Case 10) to 2104 MBtu/hr for the UK CAER + MEA system. Heat rejection is reduced to 2464 MBtu/hr in the UK CAER + H3-1 case, for a 27.5 % decrease compared to Case 10. Modeling outputs show that in the UK CAER process, the cooling water that is 2-5°C cooler than conventional cooling tower water can be achieved for ambient conditions common to the midwest and other regions. The results from the techno-economic assessment show that the proposed technology can be investigated further as a viable alternative to conventional CO2 capture technology. The evaluation also shows the effect of the critical parameters on the LCOE, with the main variables being the approach temperature and CO2 partial pressure increase at the flue gas inlet. A summary of the key advantages of the UK CAER Process + H3-1 case for LCOE and other economic factors compared to the DOE Case 10 is as follows: • A lower variable operating cost by $1.56/MWh ($1.08MWh less than the UK CAER Process + MEA Case), a 11.7% reduction compared to the DOE Case 10 • A lower COE by $25.32MWh ($13.94/MWh lower than the UK CAER Process + MEA Case), a 16.9% reduction compared to the DOE Case 10 • A lower LCOE by $31.94/MWh ($17.51/MWh lower than the UK CAER Process + MEA Case), a 16.9% reduction compared to the DOE Case 10 • A lower cost of CO2 captured by $18.65/tonne CO2 ($9.44/tonne CO2 lower than the UK CAER Process + MEA Case), a 30.4% reduction compared to the DOE Case 10 • A lower cost of CO2 avoided by $34.95/tonne CO2 ($18.53 tonne CO2 lower than the UK CAER Process + MEA Case), a 38.7% reduction compared to the DOE Case 10

Bhown, Abhoyjit S.↗

NASA NTRS2016

Manufacturing Process Developments for Regeneratively-Cooled Channel Wall Rocket Nozzles

Regeneratively cooled channel wall nozzles incorporate a series of integral coolant channels to contain the coolant to maintain adequate wall temperatures and expand hot gas providing engine thrust and specific impulse. NASA has been evaluating manufacturing techniques targeting large scale channel wall nozzles to support affordability of current and future liquid rocket engine nozzles and thrust chamber assemblies. The development of these large scale manufacturing techniques focus on the liner formation, channel slotting with advanced abrasive water-jet milling techniques and closeout of the coolant channels to replace or augment other cost reduction techniques being evaluated for nozzles. NASA is developing a series of channel closeout techniques including large scale additive manufacturing laser deposition and explosively bonded closeouts. A series of subscale nozzles were completed evaluating these processes. Fabrication of mechanical test and metallography samples, in addition to subscale hardware has focused on Inconel 625, 300 series stainless, aluminum alloys as well as other candidate materials. Evaluations of these techniques are demonstrating potential for significant cost reductions for large scale nozzles and chambers. Hot fire testing is planned using these techniques in the future.

Gradl, Paul↗

NASA NTRSDate not supplied

TPSAS-NF1676L-32577-DND

The ground testing of hypersonic vehicles requires the replication of the flow conditions at high speed and altitude. To produce these flow conditions, stored compressed air is expanded through a convergent-divergent nozzle to produce the required pressures and speed. However, the expansion process also cools the air, and so to match the flight temperatures, some form of heating needs to be employed. Vitiated heating is a common method, where the air is heated by burning fuel in the low speed side of the nozzle, and then oxygen is added to bring the level of O2 up to match that of standard air. The resulting flow no longer has the same composition as standard air, (except for the oxygen level), but rather contains combustion products, often referred to as vitiates as part of the mixture. The presence of these vitiates in the flow effects the wind tunnel test conditions. For example, the specific heat and molecular density are changed, the kinetics of combustion are altered and the flow features in the test article are altered. In this talk, the effects of the vitiates on the testing conditions and on the performance of test articles is described. Specific examples include the effects of molecular density on the flow, how combustion processes are altered by the presence of vitiates and how condensation of vitiates can alter the test conditions. In addition, the effect of the less common vitiates produced by arc-heated tunnels are mentioned, such as NO, non-thermal equilibrium and the presence of copper solids in the flow. Finally some thoughts on how large an effect these vitiates have on the test results are presented.

Andrew T Norris↗

NASA NTRS1994

Geminga: A cooling superfluid neutron star

We compare the recent temperature estimate for Geminga with neutron star cooling models. Because of its age (approximately 3.4 x 10(exp 5) yr), Geminga is in the photon cooling era. We show that its surface temperature (approximately 5.2 x 10(exp 5) K) can be understood by both types of neutrino cooling scenarios, i.e., slow neutrino cooling by the modified Urca process or fast neutrino cooling by the direct Urca process or by some exotic matter, and thus does not allow us to discriminate between these two competing schemes. However, for both types of scenarios, agreement with the observed temperature can only be obtained if baryon pairing is present in most, if not all, of the core of the star. Within the slow neutrino cooling scenario, early neutrino cooling is not sufficient to explain the observed low temperature, and extensive pairing in the core is necessary to reduce the specific heat and increase the cooling rate in the present photon cooling era. Within all the fast neutrino cooling scenarios, pairing is necessary throughout the whole core to control the enormous early neutrino emission which, without pairing suppression, would result in a surface temperature at the present time much lower than observed. We also comment on the recent temperature estimates for PSR 0656+14 and PSR 1055-52, which pertain to the same photon cooling era. If one assumes that all neutron stars undergo fast neutrino cooling, then these two objects also provide evidence for extensive baryon pairing in their core; but observational uncertainties also permit a more conservative interpretation, with slow neutrino emission and no pairing at all. We argue though that observational evidence for the slow neutrino cooling model (the 'standard' model) is in fact very dim and that the interpretation of the surface temperature of all neutron stars could be done with a reasonable theoretical a priori within the fast neutrino cooling scenarios only. In this case, Geminga, PSR 0656+14, and PSR 1055-52 all show evidence of baryon pairing down to their very centers.

Page, Dany↗

NASA NTRS1974

Structure and properties of a splat cooled 2024 aluminum alloy

In the investigation the alloy was melted, heated to 750 C, and atomized into fine droplets. The droplets were rapidly quenched against a heavy copper disk rotating at 1725 rpm. The resultant splat cooled flakes were screened. Three flake sizes were finally separated. Flakes of each size were separately processed. The characteristics of the splat cooling process and the properties of the obtained products are discussed. Splat cooling against a metallic substrate permits cooling rates up to about 1,000,000 deg C/sec. Increases in yield strength and tensile strength of 14 to 19% are observed for the splat products. Other improvements are connected with increases in fatigue life and stress rupture performance.

Lebo, M.↗

DOE OSTI2024

Coherent-Precipitation-Stabilized Phase Formation in Over-Stoichiometric Rocksalt-Type Li Superionic Conductors

Rationalizing synthetic pathways is crucial for material design and property optimization, especially for polymorphic and metastable phases. Over-stoichiometric rocksalt (ORX) compounds, characterized by their face-sharing configurations, are a promising group of materials with unique properties; however, their development is significantly hindered by challenges in synthesizability. Here, taking the recently identified Li superionic conductor, over-stoichiometric rocksalt Li–In–Sn–O (o-LISO) material as a prototypical ORX compound, the mechanisms of phase formation are systematically investigated. It is revealed that the spinel-like phase with unconventional stoichiometry forms as coherent precipitate from the high-temperature-stabilized cation-disordered rocksalt phase upon fast cooling. This process prevents direct phase decomposition and kinetically locks the system in a metastable state with the desired face-sharing Li configurations. This insight enables us to enhance the ionic conductivity of o-LISO to be >1 mS cm -1 at room temperature through low-temperature post-annealing. This work offers insights into the synthesis of ORX materials and highlights important opportunities in this new class of materials.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Pitting Corrosion in 316L Stainless Steel Fabricated by Laser Powder Bed Fusion Additive Manufacturing: A Review and Perspective

Abstract 316L stainless steel (316L SS) is a flagship material for structural applications in corrosive environments, having been extensively studied for decades for its favorable balance between mechanical and corrosion properties. More recently, 316L SS has also proven to have excellent printability when parts are produced with additive manufacturing techniques, notably laser powder bed fusion (LPBF). Because of the harsh thermo-mechanical cycles experienced during rapid solidification and cooling, LPBF processing tends to generate unique microstructures. Strong heterogeneities can be found inside grains, including trapped elements, nano-inclusions, and a high density of dislocations that form the so-called cellular structure. Interestingly, LPBF 316L SS not only exhibits better mechanical properties than its conventionally processed counterpart, but it also usually offers much higher resistance to pitting in chloride solutions. Unfortunately, the complexity of the LPBF microstructures, in addition to process-induced defects, such as porosity and surface roughness, have slowed progress toward linking specific microstructural features to corrosion susceptibility and complicated the development of calibrated simulations of pitting phenomena. The first part of this article is dedicated to an in-depth review of the microstructures found in LPBF 316L SS and their potential effects on the corrosion properties, with an emphasis on pitting resistance. The second part offers a perspective of some relevant modeling techniques available to simulate the corrosion of LPBF 316L SS, including current challenges that should be overcome.

Voisin, T. (ORCID:0000000287462659)↗

DOE OSTI2021

Deep mitigation of CO 2 and non-CO 2 greenhouse gases toward 1.5 °C and 2 °C futures

Stabilizing climate change well below 2 °C and towards 1.5 °C requires comprehensive mitigation of all greenhouse gases (GHG), including both CO 2 and non-CO 2 GHG emissions. Here we incorporate the latest global non-CO 2 emissions and mitigation data into a state-of-the-art integrated assessment model GCAM and examine 90 mitigation scenarios pairing different levels of CO 2 and non-CO 2 GHG abatement pathways. We estimate that when non-CO 2 mitigation contributions are not fully implemented, the timing of net-zero CO 2 must occur about two decades earlier. Conversely, comprehensive GHG abatement that fully integrates non-CO 2 mitigation measures in addition to a net-zero CO 2 commitment can help achieve 1.5 °C stabilization. While decarbonization-driven fuel switching mainly reduces non-CO 2 emissions from fuel extraction and end use, targeted non-CO 2 mitigation measures can significantly reduce fluorinated gas emissions from industrial processes and cooling sectors. Our integrated modeling provides direct insights in how system-wide all GHG mitigation can affect the timing of net-zero CO 2 for 1.5 °C and 2 °C climate change scenarios.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2021

Direct evidence of microstructure dependence of magnetic flux trapping in niobium

Abstract Elemental type-II superconducting niobium is the material of choice for superconducting radiofrequency cavities used in modern particle accelerators, light sources, detectors, sensors, and quantum computing architecture. An essential challenge to increasing energy efficiency in rf applications is the power dissipation due to residual magnetic field that is trapped during the cool down process due to incomplete magnetic field expulsion. New SRF cavity processing recipes that use surface doping techniques have significantly increased their cryogenic efficiency. However, the performance of SRF Nb accelerators still shows vulnerability to a trapped magnetic field. In this manuscript, we report the observation of a direct link between flux trapping and incomplete flux expulsion with spatial variations in microstructure within the niobium. Fine-grain recrystallized microstructure with an average grain size of 10–50 µm leads to flux trapping even with a lack of dislocation structures in grain interiors. Larger grain sizes beyond 100–400 µm do not lead to preferential flux trapping, as observed directly by magneto-optical imaging. While local magnetic flux variations imaged by magneto-optics provide clarity on a microstructure level, bulk variations are also indicated by variations in pinning force curves with sequential heat treatment studies. The key results indicate that complete control of the niobium microstructure will help produce higher performance superconducting resonators with reduced rf losses 1 related to the magnetic flux trapping.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2021

Reducing sputter induced stress and damage for efficient perovskite/silicon tandem solar cells

Reducing damages caused by sputtering of transparent conductive oxide (TCO) electrodes is critical in achieving highly efficient and stable perovskite/silicon tandem solar cells. Here we study the sputter caused damage to bathocuproine (BCP), which is widely used in highly efficient p-i-n structure single junction perovskite solar cells. While BCP buffer layer protects the underneath layers from damage, itself can be damaged by sputtering of TCOs at a wide range of target-substrate distances, supported by molecular dynamic simulation. More intriguingly, it is observed that TCO easily peeled off after sputtering when the sputtering target is close to substrate. This is ascribed to formation of stress during cooling down process after sputtering due to different thermal expansion coefficients of the layers. Our studies explain why tin oxide (SnO2) made by atomic layer deposition can replace BCP for a much better tandem device performance. SnO2 has high affinity with sputtered TCO electrode to suppress peeling-off issue and has higher bond energy to resist sputter induced damage, thus it allows a wider window of target-substrate distances than BCP during TCO sputtering. Ultimately, we demonstrate an efficient perovskite/silicon monolithic tandem solar cell with efficiency of 26.0% to illustrate the beneficial effects of reduced stress and damage.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

A model for radiative heating of a high-Z pusher

Several approaches to Inertial Confinement Fusion (ICF), including double-shell, pushered-single-shell, and the Revolver designs, have fuel surrounded by pushers made from high-Z materials. An advantage of these designs is that radiation emitted by the hot fuel will be absorbed and re-radiated into the fuel to reduce cooling. This process is referred to as radiation-trapping, and it lowers the fuel temperature required for ignition. To elucidate the physics of radiation trapping, a simplified model comprising a set of coupled differential equations has been developed to model the arbitrary time-dependent wall temperature from the Hammer and Rosen solution [J. H. Hammer and M. D. Rosen, Phys. Plasmas 10, 1829 (2003)] to a Marshak wave. The derivation of the model and a set of analytical power-law solutions will be presented. A discussion on numerical implementation of the differential equations into a model for burn in ICF capsules is also included.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2022

Lawson Criterion for Ignition Exceeded in an Inertial Fusion Experiment

For more than half a century, researchers around the world have been engaged in attempts to achieve fusion ignition as a proof of principle of various fusion concepts. Following the Lawson criterion, an ignited plasma is one where the fusion heating power is high enough to overcome all the physical processes that cool the fusion plasma, creating a positive thermodynamic feedback loop with rapidly increasing temperature. In inertially confined fusion, ignition is a state where the fusion plasma can begin “burn propagation” into surrounding cold fuel, enabling the possibility of high energy gain. While “scientific breakeven” (i.e., unity target gain) has not yet been achieved (here target gain is 0.72, 1.37 MJ of fusion for 1.92 MJ of laser energy), this work reports the first controlled fusion experiment, using laser indirect drive, on the National Ignition Facility to produce capsule gain (here 5.8) and reach ignition by nine different formulations of the Lawson criterion.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS1972

The effect of an isotopic non-equilibrium plasma on electron temperature measurements

Electron temperatures determined by electrostatic probe, diffuse resonance, and radar backscatter techniques in an isotropic two temperature plasma are presented. Plasma models corresponding to the addition of a minor component of energetic electrons, and models corresponding to a process that cools a fraction of the ionospheric electrons are considered. The diffuse resonance temperature is found to lie between the probe and radar backscatter temperatures. The isotropic models corresponding to the addition of energetic electrons cannot support the reported discrepancies between radio wave and probe electron temperature measurements. Temperature differences similar to the observed differences can be produced by models with a fraction of the electrons at a temperature cooler than that of the main component of electrons.

Benson, R. F.↗

NASA NTRS1973

Shield materials recommended for space power nuclear reactors

Lithium hydride is recommended for neutron attenuation and depleted uranium is recommended for gamma ray attenuation. For minimum shield weights these materials must be arranged in alternate layers to attenuate the secondary gamma rays efficiently. In the regions of the shield near the reactor, where excessive fissioning occurs in the uranium, a tungsten alloy is used instead. Alloys of uranium such as either the U-0.5Ti or U-8Mo are available to accommodate structural requirements. The zone-cooled casting process is recommended for lithium hydride fabrication. Internal honeycomb reinforcement to control cracks in the lithium hydride is recommended.

Kaszubinski, L. J.↗

NASA NTRS1973

Effect of an isotropic nonequilibrium plasma on electron temperature measurements.

The electron temperatures that would be determined (using the conventional single-temperature analysis) by the electrostatic probe, the diffuse resonance, and the radar backscatter techniques in an isotropic two-temperature plasma are presented. Plasma models corresponding to the addition of a minor component of energetic electrons and models corresponding to a process that cools a fraction of the ionospheric electrons are considered. The diffuse resonance temperature is found to lie between the probe and radar backscatter temperatures. The isotropic models corresponding to the addition of energetic electrons cannot support the reported discrepancies between radio wave and probe electron temperature measurements. Temperature differences similar to the observed differences can be produced by models with a fraction of the electrons at a temperature cooler than that of the main component of electrons. These models, however, are difficult to explain in terms of present understanding of the ionospheric plasma.

Benson, R. F.↗

NASA NTRS1974

Abstracts, Third Space Processing Symposium, Skylab results

Skylab experiments results are reported in abstracts of papers presented at the Third Space Processing Symposium. Specific areas of interest include: exothermic brazing, metals melting, crystals, reinforced composites, glasses, eutectics; physics of the low-g processes; electrophoresis, heat flow, and convection demonstrations flown on Apollo missions; and apparatus for containerless processing, heating, cooling, and containing materials.

Source record↗

NASA NTRS1977

Electric heating for metal surface hardening

Electrical element heats only desired area and permits precise control of temperature and cooling rate. Process serves as alternative to flame hardening for treating localized areas.

Lockman, N. L.↗