Localized Corrosion and Stress Corrosion Cracking: Prediction, Prevention, and Advanced Materials for Protection.
Abstract not provided.
Schaller, Rebecca↗
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Volatile Hydroxide Species of Common Protective Oxides and their Role in High Temperature Corrosion
Thermodynamic data for volatile hydroxides and oxyhydroxides formed from the reaction of water vapor with Cr2O3, SiO2, A12O3, Y2O3,. and ZrO2 were assembled. The volatile species formed at temperatures between 800 and 2200K in model combustion environments containing 10% water vapor and 10% oxygen at 1 and 10 bar total pressure were calculated using free energy minimization techniques. Assuming an acceptable maximum vapor pressure limit for volatile species of 10 bar, an upper use temperature for these oxides was determined at 1 and 10 bar total pressure. The dependence of these volatile species on both water vapor and oxygen pressure was determined.
Opila, Elizabeth J.↗
Joint Test Plan for Gas Dynamic Spray Technology Demonstration
Air Force Space Command (AFSPC) and NASA have similar missions, facilities, and structures located in similar harsh environments. Both are responsible for a number of facilities/structures with metallic structural and non-structural components in highly and moderately corrosive environments. Regardless of the corrosivity of the environment, all metals require periodic maintenance activity to guard against the insidious effects of corrosion and thus ensure that structures meet or exceed design or performance life. The standard practice for protecting metallic substrates in atmospheric environments is the use of an applied coating system. Current coating systems used across AFSPC and NASA contain volatile organic compounds (VOCs) and hazardous air pollutants (HAPs). These coatings are subject to environmental regulations at the Federal and State levels that limit their usage. In addition, these coatings often cannot withstand the high temperatures and exhaust that may be experienced by AFSPC and NASA structures. In response to these concerns, AFSPC and NASA have approved the use of thermal spray coatings (TSCs). Thermal spray coatings are extremely durable and environmentally friendly coating alternatives, but utilize large cumbersome equipment for application that make the coatings difficult and time consuming to repair. Other concerns include difficulties coating complex geometries and the cost of equipment, training, and materials. Gas Dynamic Spray (GDS) technology (also known as Cold Spray) will be evaluated as a smaller, more maneuverable repair method as well as for areas where thermal spray techniques are not as effective. The technology can result in reduced maintenance and thus reduced hazardous materials/wastes associated with current processes. Thermal spray and GDS coatings also have no VOCs and are environmentally preferable coatings. To achieve a condition suitable for the application of a coating system, including GDS coatings, the substrate must undergo some type of surface preparation and/or depainting operation to ensure adhesion of the new coating system. The GDS unit selected for demonstration has a powder feeding system that can be used for surface preparation or coating application. The surface preparation feature will also be examined. The primary objective of this effort is to demonstrate GDS technology as a repair method for TSCs. The project will also determine the optimal GDS coating thickness for acceptable performance. Successful completion of this project will result in approval of GDS technology as a repair method for TSCs at AFSPC and NASA installations and will improve corrosion protection at critical systems, facilitate easier maintenance activity, extend maintenance cycles, eliminate flight hardware contamination, and reduce the amount of hazardous waste generated.
Lewis, Pattie↗
Enhanced stability of silicon for photoelectrochemical water oxidation through self-healing enabled by an alkaline protective electrolyte
Alkaline electrolytes impede the corrosion of Si photoanodes under positive potentials and/or illumination, due to the formation of a SiO x layer that etches 2–3 orders of magnitude more slowly than Si. Hence during water oxidation under illumination, pinholes in protection layers on Si photoanodes result in the local formation of a protective, stabilizing passive oxide on the Si surface. However, operation under natural diurnal insolation cycles additionally requires protection strategies that minimize the dark corrosive etching rate of Si at pinholes. We show herein that addition of [Fe(CN) 6 ] 3- to 1.0 M KOH(aq) results in a self-healing process that extends the lifetime to >280 h of an np + -Si(100) photoanode patterned with an array of Ni catalyst islands operated under simulated day/night cycles. The self-healing [Fe(CN) 6 ] 3- additive caused the exposed Si(100) surface to etch >180 times slower than the Si etch rate in 1.0 M KOH(aq) alone. No appreciable difference in etch rate or facet preference was observed between Si(100) and Si(111) surfaces in 1.0 M KOH(aq) with [Fe(CN) 6 ] 3- , indicating that the surface conformally oxidized before Si dissolved. The presence of [Fe(CN) 6 ] 3- minimally impacted the faradaic efficiency or overpotential of p + -Si/Ni electrodes for the oxygen-evolution reaction.
25 ENERGY STORAGE↗
Predicted Fracture Tendency of Naturally Occurring Aluminum Surface Coatings under Tensile Loading
Naturally occurring coatings on aluminum metal, such as its oxide or hydroxide, serve to protect the material from corrosion. Understanding the conditions under which these coatings mechanically fail is therefore expected to be an important aspect of predictive models for aluminum component lifetimes. To this end, we develop and apply a molecular dynamics (MD) modeling framework for conducting tension tests that is capable of isolating factors governing the mechanical strength as a function of coating chemistry, defect morphology, and variables associated with the loading path. We consider two representative materials, including γ-Al 2 O 3 and γ-Al(OH) 3 (i.e., oxide and hydroxide), both of which form readily as aluminum surface coatings. Our results indicate that defects have a significant bearing on the strength of aluminum oxide, with grain boundaries serving to reduce the strain at failure from ε zz = 0.300 to 0.219, relative to perfect single crystal. Our simulations also predict that porosity lowers the elastic stiffness and yield strength of the oxide. Relative to perfect crystal, we find porosity factors of 5%, 10% and 20% decrease the yield stress by 26%, 36% and 53%, respectively. MD predicts that perfect hydroxide and oxide single crystal have respective strains at failure of 0.08 and 0.31 under tensile uniaxial strain loading, and that the corresponding yield stresses are respectively 1.6 and 11.1 GPa. These data indicate that the hydroxide is substantially more susceptible to mechanical failure than the oxide. Our results, coupled with literature findings that indicate hot and humid conditions favor formation of hydroxide and defective oxide coatings, indicate the potential for a complicated dependence of aluminum corrosion susceptibility and stress corrosion cracking on aging history.
36 MATERIALS SCIENCE↗
Corrosion Prevention in Copper Combustion Chamber Liners of Liquid Oxygen/Methane Booster Engines
Prior research conducted by United Technologies Research Center and Rockwell International Rocketdyne Division encountered severe copper corrosion while flowing hydrocarbon fuels through copper cooling tubes. These experimental results have very important implications for the development of low-cost, regeneratively cooled, oxygen/hydrocarbon bipropellant booster engines. Aerojet TechSystems undertook a program sponsored by NASA/Lewis Research Center in 1986 with two objectives: (1) to define the corrosive interaction process that occurs between hydrocarbon fuels and copper combustion chamber liner materials, using both static and dynamic test methods, and (2) to identify and demonstrate protective measures against this corrosive process. The results of the first program task demonstrated that the most damaging corrosive process was caused by trace amounts of sulfur-containing impurities in the hydrocarbon fuel which react with the copper chamber liner material to form cuprous sulfide (Cu2S), as reported in Paper No. AlAA 88-3215. Experiments were conducted which demonstrated this corrosive process with Mil-Spec RP-1, propane, and methane fuels in contact with OFHC, NASA-Z, and ZrCu coppers. The preliminary results of the second program task demonstrated that electrodeposited gold and platinum coatings held promise of preventing corrosion of copper chamber liners by methane contaminated with sulfur-containing impurities, as reported in Paper No. AIAA 89-2738. Experiments were conducted which demonstrated greatly reduced corrosion of copper by hydrogen sulfide (H2S) and methyl mercaptan (CH3SH) as measured impurities in methane. This paper presents the concluding, confirmatory results from the second program task. The efficacy of a protective gold coating on NASA-Z copper cooling channel walls was conclusively demonstrated. Tests were conducted in the Aerojet Carbothermal Test Facility which provide realistic simulations of booster engine cooling channel conditions such as temperature, pressure, flow velocity, and heat flux. Dynamic test series were performed with methane containing 5 and 10 ppm (by volume) hydrogen sulfide. Gold-plated and unplated copper alloy specimens were evaluated. The tests demonstrated that gold coatings were effective in preventing corrosion of the copper. Posttest metallographic examinations of the unplated specimens showed severe corrosion as a result of reaction with the sulfur containing contaminant in the fuel. In contrast, posttest metallographic examination of the gold-coated specimens showed no corrosion under similar operating conditions. The findings from metallurgical and chemical analyses of the copper specimens, chemical analysis of the methane, and description of all test conditions are provided. Conclusions are reached as to the efficacy of the plating methods and the effectiveness of the metal coatings in the prevention of corrosion in hydrocarbon-fueled booster engine combustion chamber liners.
S D Rosenberg↗
Sporting Good Lubricants
Sun Coast Chemicals was originally contracted by Lockheed Martin Space Operations to formulate a spray lubricant free of environmental drawbacks for the Mobile Launch Platform used to haul the Space Shuttle from the Kennedy Space Center Vehicle Assembly Building to a launch pad. From this work, Sun Coast introduced Train Track Lubricant, Penetrating Spray Lube, and Biodegradable Hydraulic Fluid. Based on the original lubricant work, two more products have also been introduced. First, the X-1R Super Gun Cleaner and Lubricant protects guns from rust and corrosion caused by environmental conditions. Second, the X-1R Tackle Pack, endorsed by both fresh and saltwater guides and certain reel manufacturers, penetrates, cleans, reduces friction, lubricates, and provides extra protection against rust and corrosion.
Source record↗
Electrochemical, Polarization, and Crevice Corrosion Testing of Nitinol 60, A Supplement to the ECLSS Sustaining Materials Compatibility Study
In earlier trials, electrochemical test results were presented for six noble metals evaluated in test solutions representative of waste liquids processed in the Environmental Control and Life Support System (ECLSS) aboard the International Space Station (ISS). Subsequently, a seventh metal, Nitinol 60, was added for evaluation and subjected to the same test routines, data analysis, and theoretical methodologies. The previous six test metals included three titanium grades, (commercially pure, 6Al-4V alloy and 6Al-4V low interstitial alloy), two nickel-chromium alloys (Inconel(RegisteredTrademark) 625 and Hastelloy(RegisteredTrademark) C276), and one high-tier stainless steel (Cronidur(RegisteredTrademark) 30). The three titanium alloys gave the best results of all the metals, indicating superior corrosive nobility and galvanic protection properties. For this current effort, the results have clearly shown that Nitinol 60 is almost as noble as titanium, being very corrosion-resistant and galvanically compatible with the other six metals electrochemically and during long-term exposure. is also quite noble as it is very corrosion resistant and galvanically compatible with the other six metals from both an electrochemical perspective and long-term crevice corrosion scenario. This was clearly demonstrated utilizing the same techniques for linear, Tafel and cyclic polarization, and galvanic coupling of the metal candidate as was done for the previous study. The high nobility and low corrosion susceptibility for Nitinol 60 appear to be intermediate to the nickel/chromium alloys and the titanium metals with indications that are more reflective of the titanium metals in terms of general corrosion and pitting behavior.
Lee, R. E.↗
Galvanic Liquid Applied Coating Development for Protection of Steel in Concrete
Corrosion of reinforcing steel in concrete is a major problem affecting NASA facilities at Kennedy Space Center (KSC), other government agencies, and the general public. Problems include damage to KSC launch support structures, transportation and marine infrastructures, as well as building structures. A galvanic liquid applied coating was developed at KSC in order to address this problem. The coating is a non-epoxy metal rich ethyl silicate liquid coating. The coating is applied as a liquid from initial stage to final stage. Preliminary data shows that this coating system exceeds the NACE 100 millivolt shift criterion. The remainder of the paper details the development of the coating system through the following phases: Phase I: Development of multiple formulations of the coating to achieve easy application characteristics, predictable galvanic activity, long-term protection, and minimum environmental impact. Phase II: Improvement of the formulations tested in Phase I including optimization of metallic loading as well as incorporation of humectants for continuous activation. Phase III: Application and testing of improved formulations on the test blocks. Phase IV: Incorporation of the final formulation upgrades onto large instrumented structures (slabs).
Curran, Joseph John↗
Chemical processes involved in the initiation of hot corrosion of B-1900 and NASA-TRW VIA
Sodium surface-induced hot corrosion of B-1900 and NASA-TRW VIA alloys at 900 C has been studied, with special attention to the chemical reactions during and immediately after the induction period. Thermogravimetric tests were run and data were obtained by chemical analysis of water soluble metal salts and of residual sulfate. Surface analyses of hot corroded samples were obtained by spectroscopic techniques (ESCA). A chemical mechanism for elucidating Na2SO4-induced hot corrosion is proposed indicating that hot corrosion is initiated by basic fluxing of the protective Al2O3 scale. The sequential, catastrophic corrosion results from molybdenum content. The self-sustaining feature is a consequence of the cyclic nature of the acidic fluxing. It is believed that the mechanism is applicable not only to laboratory results, but also to the practical problem of hot corrosion encountered in gas turbine engines.
Fryburg, G. C.↗
Materials Science Corrosion Internship Overview
The overarching purpose of this semester-long internship at the National Aeronautics and Space Administration's (NASA) John F. Kennedy Space Center (KSC) was to study the impacts of corrosion regarding the development of ground support equipment (GSE), launch support structures, and flight hardware in aid of the Space Launch System (SLS) and Orion program. Environmental corrosion is known as one of the largest material degradation issues for any structure comprised of metal on the Space Coast and requires the initiation of special protective measures for proper corrosion mitigation. The four (4) projects to be described were conducted with NASA Civil Servants and NASA Contractors who provided necessary resources to ensure the highest quality of data acquisition and knowledge transfer. The main objective shared between all four (4) of the following projects was to assess the modes by which corrosion takes place in multiple environments as well as the methods by which these modes of corrosion can be reduced for the enhancement of the mechanical, structural, and chemical compatibility of those respective environments with different candidate metals. A multitude of test methods were performed over the duration of this internship to assess the corrosive properties of these different candidate metals.
Ground Systems Development and Operations↗
Anti-Corrosive Powder Particles
The National Aeronautics and Space Administration (NASA) seeks partners for a new approach in protecting embedded steel surfaces from corrosion. Corrosion of reinforced steel in concrete structures is a significant problem for NASA structures at Kennedy Space Center (KSC) because of the close proximity of the structures to salt spray from the nearby Atlantic Ocean. In an effort to minimize the damage to such structures, coatings were developed that could be applied as liquids to the external surfaces of a substrate in which the metal structures were embedded. The Metallic Pigment Powder Particle technology was developed by NASA at KSC. This technology combines the metallic materials into a uniform particle. The resultant powder can be sprayed simultaneously with a liquid binder onto the surface of concrete structures with a uniform distribution of the metallic pigment for optimum cathodic protection of the underlying steel in the concrete. Metallic Pigment Powder Particle technology improves upon the performance of an earlier NASA technology Liquid Galvanic Coating (U.S. Patent No. 6,627,065).
Parker, Donald↗
Designing Cladded Components for High Temperature Nuclear Service: Part II—Design Rules
The challenge of using existing ASME Section III, Division 5, class A metallic materials for the construction of structural components of advanced reactors with corrosive coolants could be mitigated by allowing designers to use cladding to protect the base material from corrosion. However, the existing Section III, Division 5 rules provide no guidance on the evaluation of strain accumulation and creep-fatigue damage in cladded components. The availability of design rules for cladded components that do not require long-term clad material testing could promote the application of the cladding approach to accelerate the deployment schedule of these advanced reactor systems. To avoid long-term properties for the clad materials Part I of this work proposes two approximate design analysis methods for two types of clad materials—soft clads that creep much faster and have lower yield stress than the class A base material, and hard clads that creep much slower and have higher yield stress than the class A base material. The proposed analysis methods approximate the response of a soft clad by treating it as perfectly compliant and of a hard clad by treating it as linear elastic. Based on these approximate design analysis strategies this Part II develops a complete set of design rules for class A components cladded with either soft or hard clad materials. In conclusion, Part II discusses the reasoning behind the proposed design rules and uses example finite element analyses of representative reactor components to illustrate the use of these design methods.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
Fail-Safe Pressure Plug
Protective plug resists slowly built-up pressure or automatically releases itself if pressure rises suddenly. Seals out moisture at pressures ranging from 50 micrometers of mercury to 200 pounds per square inch. Designed to seal throat of 38 Reaction Control Thrusters on Space Shuttle protecting internal components from corrosion. Plug conforms to contour of nozzle throat, where O-ring forms pressure seal. After plug inserted, cover attached by use of cover-fitting assembly. Modified versions useful in protecting engines, pumps, reaction vessels, and other industrial equipment during shipment and maintenance.
Svejkovsky, Paul A.↗
Analysis of Tank 38H (HTF-38-21-24, -25) and Tank 43H (HTF-43-21-26, -27) Samples for Support of the Enrichment Control and Corrosion Control Programs
Feed limits have been established for the 2H-Evaporator system to ensure nuclear criticality is not possible and corrosion is minimized. These limits are protected by the Enrichment Control Program (ECP) and the Corrosion Control Program (CCP) that require periodic sampling and analysis to confirm that the waste supernate composition stays within the limits. Savannah River Remediation (SRR) obtained samples from two different heights within each of the two waste tanks supporting the 2H-Evaporator operations on March 26, 2021. The Tank 38H (evaporator drop tank) and Tank 43H (evaporator feed tank) samples were received by the Savannah River National Laboratory (SRNL) Shielded Cells on March 26, 2021. Analysis of these samples provides information necessary for determining compliance with the ECP and CCP. The sample characterization was requested via a Technical Task Request (TTR) and conducted based on a Task Technical and Quality Assurance Plan (TTQAP).
12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
Sodium sulfate - Deposition and dissolution of silica
The hot-corrosion process for SiO2-protected materials involves deposition of Na2SO4 and dissolution of the protective SiO2 scale. Dew points for Na2SO4 deposition are calculated as a function of pressure, sodium content, and sulfur content. Expected dissolution regimes for SiO2 are calculated as a function of Na2SO4 basicity. Controlled-condition burner-rig tests on quartz verify some of these predicted dissolution regimes. The basicity of Na2SO4 is not always a simple function of P(SO3). Electrochemical measurements of an (Na2O) show that carbon creates basic conditions in Na2SO4, which explains the extensive corrosion of SiO2-protected materials containing carbon, such as SiC.
Jacobson, Nathan S.↗
Fighting Corrosion
Reinforced concrete structures such as bridges, parking decks, and balconies are designed to have a service life of over 50 years. All too often, however, many structures fall short of this goal, requiring expensive repairs and protection work earlier than anticipated. The corrosion of reinforced steel within the concrete infrastructure is a major cause for this premature deterioration. Such corrosion is a particularly dangerous problem for the facilities at NASA s Kennedy Space Center. Located near the Atlantic Ocean in Florida, Kennedy is based in one of the most corrosive-prone areas in the world. In order to protect its launch support structures, highways, pipelines, and other steel-reinforced concrete structures, Kennedy engineers developed the Galvanic Liquid Applied Coating System. The system utilizes an inorganic coating material that slows or stops the corrosion of reinforced steel members inside concrete structures. Early tests determined that the coating meets the criteria of the National Association of Corrosion Engineers for complete protection of steel rebar embedded in concrete. Testing is being continued at the Kennedy's Materials Science Beach Corrosion Test Site.
Source record↗
Cyclic Oxidation and Hot Corrosion of NiCrY-Coated Disk Superalloys
Powder metallurgy disk superalloys have been designed for higher engine operating temperatures through improvement of their strength and creep resistance. Yet, increasing disk application temperatures to 704 degrees Centigrade and higher could enhance oxidation and activate hot corrosion in harmful environments. Protective coatings could be necessary to mitigate such attack. Cylindrical coated specimens of disk superalloys LSHR and ME3 were subjected to thermal cycling to produce cyclic oxidation in air at a maximum temperature of 760 degrees Centigrade. The effects of substrate roughness and coating thickness on coating integrity after cyclic oxidation were considered. Selected coated samples that had cyclic oxidation were then subjected to accelerated hot corrosion tests. This cyclic oxidation did not impair the coating's resistance to subsequent hot corrosion pitting attack.
protective coating↗