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At least 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Zirconium Carbide Mediates Coke‐Resistant Methane Dry Reforming on Nickel‐Zirconium Catalysts

Abstract Graphitic deposits anti‐segregate into Ni 0 nanoparticles to provide restored CH 4 adsorption sites and near‐surface/dissolved C atoms, which migrate to the Ni 0 /ZrO 2 interface and induce local Zr x C y formation. The resulting oxygen‐deficient carbidic phase boundary sites assist in the kinetically enhanced CO 2 activation toward CO(g). This interface carbide mechanism allows for enhanced spillover of carbon to the ZrO 2 support, and represents an alternative catalyst regeneration pathway with respect to the reverse oxygen spillover on Ni‐CeZr x O y catalysts. It is therefore rather likely on supports with limited oxygen storage/exchange kinetics but significant carbothermal reducibility.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Elucidating the Active Site and the Role of Alkali Metals in Selective Hydrodeoxygenation of Phenols over Iron-Carbide-based Catalyst

In this study, iron-carbide-based catalysts have been explored in the selective hydrodeoxygenation (HDO) of phenol, aiming at elucidating the role of active site and alkali metal. Complementary characterization such as X-ray diffraction, X-ray photoelectron spectroscopy, high-resolution transmission electron microscopy, and scanning transmission electron microscopy coupled with electron energy loss spectroscopy, together with catalytic evaluations revealed a rapid structural reconstruction of iron carbide (Fe 3 C) catalysts, leading to a stable defective graphene-covered metallic Fe active phase (G@Fe) under reaction conditions. Further studies using different alkali metals (i.e., Na, K, and Cs) revealed that alkali metals showed negligible effect on the phase transformation of Fe 3 C. However, the reconstructed G@Fe doped with alkali metals inhibited the tautomerization, a facile reaction pathway to saturation of the aromatic ring, leading to enhanced selectivity to arene. The extent of inhibition of tautomerization or selectivity to arene was closely related to the degree of electron donation of alkali metal to Fe.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Effects of iron carbide crystal phases and dopants on the conversions of CO 2 into ethylene

The density functional theory method was used to investigate the conversions of CO 2 to ethylene formation on two common iron carbide surfaces: Fe 3 C(0 1 0) and Fe 5 C 2 (1 1 1). Based on the structure relaxation of reaction intermediates and the elementary reaction transition states. We deduced the most competitive reaction pathways for ethylene production. The main CO 2 -to-ethylene routes and the competition of side products, CO and CH 4 , are discussed. Our analyses showed that CO 2 conversion is surface structure sensitive, whereas CH 4 and C2+ hydrocarbon formations depend on the reactivity of native C atoms in the carbides. To modify the intrinsic catalyst performance, mixing dopants in Fe catalysts is an effective strategy. Furthermore, we demonstrate that doping Zn and Zr can alter the local electronic structure and enhance CO 2 adsorption on the catalyst surface.

CO2 hydrogenation↗
DOE OSTI2020

Densification and oxidation behavior of spark plasma sintered Hafnium Diboride-Hafnium Carbide composite

This study reports on the sintering and oxidation behaviors of Hafnium Diboride (HfB 2 ) and Hafnium Carbide (HfC) based ultra-high temperature ceramic (UHTC) composites. Pure Hafnium Diboride, Hafnium Carbide, and HfB 2 -50 vol% HfC composite were consolidated using spark plasma sintering (SPS) without the use of sintering aids. HfB 2 -HfC composite displayed a high sintered density of 98% as compared to 87% density of pure HfB 2 . The increased density of the HfB 2 -HfC composite is attributed to the bimodal powder distribution, which allowed for the smaller HfC particle to occupy the voids between the larger HfB 2 particles resulting in improved packing efficiency. Moreover, the higher planar surface energy, for the (111) and the (200) planes for HfC, contributed to the smaller HfC particle being a significant driving force in the sintering process. Oxidation studies of each material were carried out by exposing them to a high-speed plasma jet in a temperature exceeding 2700 °C. The results of these studies show an improved oxidation resistance of HfB 2 -HfC composite by 54% and 70% over pure HfC and HfB 2 , respectively. The enhanced oxidation behavior is attributed to B 2 O 3 filling in the porosity between the HfO 2 scale and protecting the underlying material. This study provides a new alternative to improve the sinterability of UHTC diborides by introducing another UHTC (i.e., HfC) to form a fully dense composite without sintering aid and superior oxidation resistance.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Direct ink writing of boron carbide monoliths

Direct ink writing – an extrusion-based additive manufacturing process – followed by pressureless sintering was investigated to produce boron carbide monoliths. The effects of ceramic powder loading and Pluronic binder concentration on the rheology of boron carbide pastes were studied and linked to both processing behaviour and final outcome in terms of sintered density and hardness. The effects of printing parameters, in particular orifice diameter and printing speed, were also investigated. Reducing the size of the extrusion nozzle from 584 μm to 406 μm led to significantly better shape retention, lower surface roughness, as well as higher density and hardness. A 203 μm printing orifice was also trialled but was unsuccessful due to faster drying kinetics that occurred with smaller ceramic struts resulting in rapid warping and nozzle clogging. Carbon-black – 8 wt% relative to B 4 C – acted as an effective sintering aid to increase both density and hardness. After optimisation of feedstock and printing parameters, few-layer samples (3–5 layers) had a density as high as ~ 97 % TD and a hardness of ~ 30 GPa. On the other hand, 18-layer specimens had a sintered density of ~ 87 % TD, despite a fully dense microstructure, due to the formation of a 3D array of inter-strut pores. Nevertheless, several issues that arose during manufacturing and post-processing were detrimental to the density and structural integrity of printed specimens; these issues were identified, discussed, and suggestions for future work are provided in this report.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Synthesis of high-entropy carbides from multi-metal polymer precursors

Three compositions of high-entropy carbides, (TiHfVNbTa)C, (TiZrHfNbTa)C and (TiZrNbTaW)C were synthesized via a modified Pechini process, in which citric acid served as both a cation chelating agent and a carbon source. Through pyrolysis and spark plasma sintering, single phase high-entropy carbides were formed from the homogeneous precursors at a relatively low temperature of 1800 °C. The dispersion of cations in the polymer precursor facilitated shorter diffusion distances in polymer-derived materials, and thus compositional homogeneity was significantly improved relative to materials produced by a solid-state method, as quantified by a defined coefficient of variation applied to energy-dispersive X-ray spectroscopy. Finally, a finer microstructure in polymer-derived materials results in improved fracture toughness with a K IC value of 4.29 MPa·m 1/2 achieved for (TiHfVNbTa)C.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Density functional theory calculations of the mixing enthalpy of ternary uranium carbide compounds

The high melting point of uranium-zirconium carbides (U,Zr)C makes them an ideal fuel for nuclear thermal propulsion (NTP) reactors. Gaps remain in the current understanding of the U-Zr-C system due to the difficulty of conducting thermodynamic experiments at NTP operation conditions. Density functional theory calculations using the Hubbard U model (DFT+U) were performed using orbital matrix occupation (OMC) to obtain the mixing enthalpy for UC and ZrC for (U,Zr)C ternary compounds. Similarly, DFT+U calculations were also carried out for the (U,Nb)C and (U,Ta)C systems. In conclusion, the DFT results are envisioned to be used in thermodynamic assessments of the uranium carbide systems based on the CALPHAD approach to supplement the lack of experimental data for the mixing thermodynamics.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Achieving superior mechanical properties: Tailoring multicomponent microstructure in AISI 9254 spring steel through a two-stage Q&P process and nanoscale carbide integration

In the pursuit of lightweight, durable steel, we have successfully developed a multicomponent structure in AISI 9254 spring steel using a two-stage quenching and partitioning (Q&P) process. The primary objective of this process was to engineer an optimized microstructure consisting of nanobainite, martensite, and nano-carbides. Utilizing the insights gained from the results of advanced techniques such as X-ray diffraction (XRD), scanning electron microscopy (SEM), transmission electron microscopy (TEM), and atom probe tomography (APT) performed on the as-received AISI 9254 spring steel, we refined the quenching and partitioning (Q&P) path, leading to the successful establishment of a bainitic transformation for superior mechanical properties. Our tensile tests revealed a high yield strength (≈ 1600 ± 25 MPa) and ultimate tensile strength (≈ 1850 ± 50 MPa), along with considerable elongation (≈ 11.15 ± 0.25%). We also identified that pre-formed martensite lath defects and high silicon content play crucial roles during the Q&P process, preventing carbide coalescence and increasing strain-hardening capacity. Finally, this study demonstrates the potential of a Q&P process to generate high-strength, ductile steel for automotive and aerospace applications.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Cobalt Metal–Cobalt Carbide Composite Microspheres for Water Reduction Electrocatalysis

Microspheres of cobalt metal–cobalt carbide (Co–Co x C, Co x C: Co 2 C and Co 3 C) composite with carbon shells were prepared via an OH – - and Cl – -assisted polyol method and explored for electrocatalytic activity and stability for the hydrogen evolution reaction (HER) in acidic media. From our transmission electron microscopy observations, the outermost surfaces of the as-prepared Co–Co x C composites were primarily covered with Co 2 C crystallites. Our best performing electrocatalyst exhibited superior HER activity with an overpotential of 78 mV to reach a current density of -10 mA·cm –2 , a Tafel slope of 87.8 mV·dec –1 , and 1 h of electrode durability. We show that this excellent HER performance is primarily due to the superior intrinsic activity of Co 2 C, as well as the high electrical conductivity resulting from the inclusion of cobalt metal and the presence of graphitic carbon shells in and on the composite, respectively. Using both computational and experimental approaches, we determine here that the carbon-rich cobalt carbide (Co 2 C) phase is more favorable for the HER than the carbon-poor phase (Co 3 C).

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Multi-Scale Modeling for Plasma-Enhanced Ammonia Decomposition over Carbides and Nitrides

Ammonia is a carbon-free hydrogen carrier, but its decomposition typically requires high temperatures over costly Ru-based catalysts due to the large barrier for N≡N bond formation. We develop a multiscale framework combining density functional theory, zero-dimensional plasma kinetics, and microkinetic modeling to elucidate how non-thermal plasma (NTP) enables low-temperature NH 3 decomposition over Co-based carbides and nitrides, benchmarked against Ru and Co. Under thermal conditions, all catalysts are limited by N≡N bond formation, with Co 3 C(001) most active owing to its negatively charged surface, strong N* binding, and low activation barriers of N≡N bond formation. Plasma-induced vibrational excitation of NH 3 and its reactive radicals promotes a radical-driven •NH 2 –N* coupling pathway that dominates on Co 3 C(001) and Co 3 N(001), shifting the rate-limiting step to NH 3 (v1) dissociation, increasing turnover frequencies by up to 6 orders of magnitude, and reducing the temperature needed to reach a turnover frequency of 5 s –1 from >680 °C (Ru and Co under thermal condition) to 267 °C (Co 3 C) and 415 °C (Co 3 N). These results identify Co-based carbides and nitrides as promising plasma-active catalysts for energy-efficient hydrogen production from ammonia.

ammonia decomposition↗
DOE OSTI2026

Enhancing Acidic Oxygen Evolution Activity by Supporting Iridium Electrocatalysts on Tantalum Carbide

For a high-performance proton exchange membrane water electrolyzer (PEMWE), acidic oxygen evolution reaction (OER) electrocatalysts require highly dispersed iridium oxide (IrO x ) nanoparticles. Although carbon-based materials have been explored as promising supports for IrO x nanoparticles, their limited stability under harsh oxidative and acidic PEMWE conditions remains a significant challenge. Here, in this study, we report the synthesis and in situ characterization of active and durable IrOx electrocatalysts supported on electrochemically stable and electrically conducting tantalum carbide (TaC). When applied in a PEMWE, the IrO x /TaC electrocatalyst achieves a cell voltage of 1.71 V at 1.0 A cm –2 , outperforming the commercial IrO 2 catalyst (1.82 V at 1.0 A cm –2 ). Furthermore, the IrO x /TaC catalyst maintains a stable operation for 200 h at 0.5 A cm –2 with a low degradation rate of 36 μV h –1 . Density functional theory calculations further confirm that Ir–O–Ta bond formation at the IrO x /TaC interface reduces the overpotential of the OER compared to IrO 2 . This study underscores the pivotal role of supporting IrO x over stable and conducting metal carbides, providing guidance for the design of advanced acidic OER catalysts.

58 GEOSCIENCES↗
DOE OSTI2025

Multiscale, mechanistic modeling of cesium transport in silicon carbide for TRISO fuel performance prediction

Understanding cesium (Cs) transport in TRistructural ISOtropic (TRISO) particle fuel is crucial for predicting fission product release in high-temperature reactors. However, current challenges include significant scatter in diffusivity data and unexplained temperature-dependent diffusion regimes in the silicon carbide layer. This study addresses these challenges by developing a multiscale, mechanistic Cs transport model integrating atomistic simulations and phase field modeling. Our model quantifies temperature and grain size effects on Cs diffusivity, attributing experimentally observed regimes to a transition from bulk-dominated diffusivity at high temperatures to grain boundary-dominated diffusivity at lower temperatures. The model, validated against diffusion measurements and advanced gas reactor (AGR)-1 and AGR-2 post-irradiation fission product release data, enhances the predictive capability of the BISON fuel performance code. This study advances our understanding of Cs release from TRISO particles and its dependence on temperature and silicon carbide grain size, with implications for the safety and efficiency of high-temperature nuclear reactors.

BISON↗
DOE OSTI2020

Boosting the activity of transition metal carbides towards methane activation by nanostructuring

The interaction of methane with pristine surfaces of bulk MoC and Mo 2 C is known to be weak. In contrast, a series of X-ray photoelectron spectroscopy (XPS) experiments, combined with thermal desorption mass spectroscopy (TDS), for MoC y (y = 0.5–1.3) nanoparticles supported on Au(111)—which is completely inert towards CH 4 —show that these systems adsorb and dissociate CH 4 at room temperature and low CH 4 partial pressure. This industrially-relevant finding has been further investigated with accurate density functional theory (DFT) based calculations on a variety of MoC y supported model systems. The DFT calculations reveal that the MoC y /Au(111) systems can feature low C–H bond scission energy barriers, smaller than the CH 4 adsorption energy. Our theoretical results for bulk surfaces of Mo 2 C and MoC show that a simple Brønsted–Evans–Polanyi (BEP) relationship holds for C–H bond scission on these systems. However, this is not the case for methane activation on the MoC y nanoparticles as a consequence of their unique electronic and chemical properties. Finally, the discovery that supported molybdenum carbide nanoparticles are able to activate methane at room temperature paves the road towards the design of a new family of active carbide catalysts for methane activation and valorisation, with important implications in climate change mitigation and carbon cycle closure.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Overcoming the phase separation within high-entropy metal carbide by poly(ionic liquid)s

High-entropy crystalline materials are attracting more attention. In principle, high-entropy metal carbides (HMCs) that contain five or more metal ions, possess more negative free energy value during catalysis. But its preparation is challenging because of the immiscibility of multi metal cations in a single carbide solid solution. Here, a rational strategy for preparing HMC is proposed via a coordination-assisted crystallization process in the presence of Br-based poly(ionic liquids). Through this method, Mo 0.2 W 0.2 V 0.2 Cr 0.2 Nb 0.2 C nanoparticles, with a single cubic phase structure, incorporated on porous carbon, are obtained (HMC@NC). By combination of well dispersed small particle size (~4 nm), high surface area (~270 m 2 g –1 ), and high-entropy phase, HMC@NC can function as a promising catalyst for the dehydrogenation of ethylbenzene. Here, unexpected activity (EB conv.: 73%) and thermal stability (>100 h on steam) at 450 °C are observed. Such a facile synthetic strategy may inspire the fabrication of other types of HMCs for more specific tasks.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Nature of molybdenum carbide surfaces for catalytic hydrogen dissociation using machine-learned potentials: an ensemble-averaged perspective

Molybdenum carbides with an electronic structure similar to noble metals have gained attention as a promising low-cost catalyst for biomass valorization and the hydrogen evolution reaction. However, our fundamental understanding of the catalyst surface and how different phases of these catalysts behave at varying reaction conditions is limited to ground state density functional theory calculations as ab initio molecular dynamics (AIMD) is computationally prohibitive at relevant length and time scales. Here, in this work, we train a multi-atomic cluster expansion (MACE) machine-learned interatomic potentials (MLIP) to study hydrogen dissociation and dynamics over Mo, δ-MoC, α-Mo 2 C, and β-Mo 2 C surfaces at varying temperatures and hydrogen partial pressures. Our simulations identify unique and different molecular and atomic hydrogen adsorption sites on different surfaces that do not depend on the temperature. At low hydrogen pressures, the surface coverage is monolayer, which transitions to two-layer adsorption at higher pressures. We find that atomic hydrogen diffusion and recombinations are preferred over molybdenum atom hollow sites, while the diffusion over carbon-terminated facets was negligible, signifying particularly strong C–H interactions. In contrast, molecular hydrogen adsorption occurs mostly atop Mo or the bridging sites. At a comparable hydrogen loading, β-Mo 2 C (001) is the most active surface for hydrogen dissociation reaction. This work provides insights into the dynamic nature of the hydrogen dissociation chemistry and the diversity of hydrogen adsorption sites on molybdenum carbides.

08 HYDROGEN↗
DOE OSTI2023

Shock response of cobalt-based cemented tungsten carbides at pressures up to 100 GPa

In the present study, shock wave experiments are conducted on General Carbide cemented tungsten carbides with 3.7 wt.% and 6.0 wt.% cobalt binder to determine their shock compression response up to 100 GPa. A three-stage particle velocity profile is observed in the experiments -- an initial elastic-rise to the Hugoniot elastic limit (HEL), an elastic-plastic ramp indicating post-yield hardening, and finally a rise to the peak shocked Hugoniot state. The results of the experiments are used to determine the HEL, shock velocity (U s ) vs. particle velocity (u p ) Hugoniot relationship, and the longitudinal stress vs. specific volume Hugoniot relationship for the two samples. Here, the HEL for the WC 3.7wt% Co and WC 6.0wt% Co samples was determined to be ~4.45 GPa and 3.72 GPa, respectively. The U s – u p relation was determined to be U s = 4.97(0.006)+1. 446 (0.018) u p for WC 3.7 wt.% Co and U s = 4.93(0.006)+1. 454(0.017)u p for the WC 6.0 wt.% Co sample at peak particle velocities>0.75 km/s. For both WC grades, in the particle velocity regime less than ~0.75 km/s, the measured shock wave velocities were found to be larger than those predicted by the linear U s –u p Hugoniot relationship, indicating the two WC samples to preserve substantial strength in the post-yield deformation regime. Both WC grades show a catastrophic drop in shear stress carrying capacity when shocked to longitudinal stresses greater than ~70 GPa.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Sound speed measurements in shock-compressed cemented Tungsten carbides at pressures up to 100 GPa

To gain insights into thermodynamic states attained during shock compression of cemented tungsten carbide with 3.7 wt.% cobalt binder, we present results of longitudinal sound (release wave) speed measurements and their analysis at peak stresses up to 100 GPa (volumetric compression ratio ~ 15%). The sound speeds are determined using front-surface impact and release-wave overtake plate impact experimental configurations using laser interferometry. The measured sound speed data along with estimates for bulk sound speeds obtained using the fourth-order Birch-Murnaghan EoS and thermodynamics are used to determine the longitudinal moduli and shear moduli of shocked tungsten carbide at the various peak compression states attained in the experiments. Here, the longitudinal sound speeds were found to increase linearly with volume compression ratio from 6.97 ± 0.010 km/s at ambient conditions to 8.26 ± 0.156 km/s at a volume compression ratio of ~ 15%. The corresponding longitudinal elastic moduli also increase nearly linearly with the volume compression ratio but remain consistently lower than their theoretical predictions based on continuum models with no damage. Also, the sensitivity of shear moduli to pressure, as predicted by the Steinberg-Guinan model, is reduced substantially and the shear moduli of cemented WC with 3.7 wt.% Co remains nearly constant at ~ 310 GPa at the various peak compression stress states investigated in the present study.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Silicon carbide fiber composite receiver tubes manufactured by PIP process

The performance of SiC fiber composites made by a polymer infiltration and pyrolysis (PIP) process was investigated. Two types of tubular composites were manufactured using Hi-Nicalon and Nicalon-CG silicon carbide fibers infiltrated with SMP10 silicon carbide matrix. The fiber content in both composites was about 25 vol.% with an average density of 2.39 g/cc. The tubular SiC composites showed stable solar absorptance and emittance of 0.97 and 0.91, respectively, at 800 °C. The composites were thermally shocked at 900, 1000, and 1100 °C with a waterjet simulating raindrops. As a result, the hoop tensile strength of the composites revealed no loss of mechanical strength due to the thermal shock experiments up to 1100 °C.

14 SOLAR ENERGY↗