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DOE OSTI2023

Advances in 3D Geologic Modeling of Alluvial Basins with a Focus on Facies and Property Modeling

The unsaturated zone alluvium reference case is one of several geologic systems under consideration by the U.S. Department of Energy Office of Nuclear Energy for hosting repositories for spent nuclear fuel and associated waste (Sevougian et al., 2019). As noted by Mariner et al. (2018), the generic alluvial basin offers positive attributes that merit its consideration as a reference case by the Spent Fuel and Waste Science and Technology (SFWST) campaign. There are hundreds of alluvial basins and sub-basins scattered across the arid western United States (Figure 1-1). Precipitation and infiltration rates are relatively low with high evapotranspiration, resulting in vertical separation between repository and water table and thus longer transport paths to an aquifer. Accumulations of alluvial sediments within these basins are typically on the order of hundreds of meters, and locally may exceed 1,000 m in thickness, as is the case for the Deming sub-basin in southern New Mexico. A thick geologic host medium, which serves as the natural barrier system (NBS) in the conceptual model framework of a geologic disposal system, isolates the waste packages from receptors in the biosphere. Further, alluvial basin fill is typically comprised of stacked playa and lacustrine deposits along the basin axis (Perry et al., 2018). Characterized by low permeability, these layers protect the biosphere above the repository and the groundwater resources below the repository.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

NASA NTRS1985

A senstitivity study of the ground hydrologic model using data generated by an atmospheric general circulation model

The Ground Hydrologic Model (GHM) developed for use in an atmospheric general circulation model (GCM) has been refined. A series of sensitivity studies of the new version of the GHM were conducted for the purpose of understanding the role played by various physical parameters in the GHM. The following refinements have been made: (1) the GHM is coupled directly with the planetary boundary layer (PBL); (2) a bulk vegetation layer is added with a more realistic large-scale parameterization; and (3) the infiltration rate is modified. This version GHM has been tested using input data derived from a GCM simulation run for eight North America regions for 45 days. The results are compared with those of the resident GHM in the GCM. The daily average of grid surface temperatures from both models agree reasonably well in phase and magnitude. However, large difference exists in one or two regions on some days. The daily average evapotranspiration is in general 10 to 30% less than the corresponding value given by the resident GHM.

Sun, S. F.↗

NASA NTRSDate not supplied

Medium-Range River Flood Forecasts Using a Long Short-Term Memory Network

River flooding and the impacts are a concern for decision makers throughout the United States. Accurate medium-range forecasts (~3-7 days) are critical for providing advanced outlooks to emergency management officials. Unfortunately, accurately forecasting rainfall-runoff and the subsequent rise and fall within rivers remain a challenge in hydrological modeling. While complex physical modeling systems are the standard for representing the hydrological processes, they are computationally demanding and can require extensive calibration. Further, uncertainties remain in the model parameters and input data. The use of machine learning can reduce some of the computational demand while maintaining high accuracy. Therefore, this project makes use of a Long Short-Term Memory (LSTM) network which explicitly accounts for the time-dependent nature of rainfall-runoff modeling. The developed LSTM was trained to predict river gauge height, or stage height, based on time-lagged input features which include: gauge height to initialize the model, the NASA Short-term Prediction Research and Transition Center’s instance of the Land Information System (SPoRT-LIS) relative soil moisture to describe the rainfall infiltration rate, and 6-hr Multi-Radar Multi-Sensor quantitative precipitation estimate (MRMS QPE). The developed LSTM based system is then used to produce 7-day forecasts with a 6-hr temporal resolution using three different quantitative precipitation forecasts (QPF) from the NWS’s Weather Prediction Center (WPC), the NCEP Global Forecast System (GFS) model and the National Blend of Models (NBM). This trained modeling system has been implemented as an experimental product at over 100 different rivers in collaboration with at multiple National Weather Service (NWS) Forecast Offices and River Forecast Centers (RFC) across the eastern half of the United States. The developed LSTM model achieved average Nash-Sutcliffe efficiency (NSE) 0.89 higher than the equivalent medium-range National Water Model ensemble member forecast over a 7-day forecast. In addition to the initial development and evaluation, this project has continued to expand. While the initial model was developed for precipitation dominated basins, expansion of the project has taken it to basins effected by snow melt. This presentation will provide an overview of the project with focus on recent developments on incorporating snow melt processes into the model.

Andrew T. White↗

DOE OSTI2023

Interpreting inorganic compositional depth profiles to understand the rate-limiting step in vapor phase infiltration processes

Vapor phase infiltration (VPI) is a post-polymerization modification technique that infuses inorganics into polymers to create organic–inorganic hybrid materials with new properties. Much is yet to be understood about the chemical kinetics underlying the VPI process. The aim of this study is to create a greater understanding of the process kinetics that govern the infiltration of trimethyl aluminum (TMA) and TiCl 4 into PMMA to form inorganic-PMMA hybrid materials. To gain insight, this paper initially examines the predicted results for the spatiotemporal concentrations of inorganics computed from a recently posited reaction–diffusion model for VPI. This model provides insight on how the Damköhler number (reaction versus diffusion rates) and non-Fickian diffusional processes (hindering) that result from the material transforming from a polymer to a hybrid can affect the evolution of inorganic concentration depth profiles with time. Subsequently, experimental XPS depth profiles are collected for TMA and TiCl 4 infiltrated PMMA films at 90 °C and 135 °C. The functional behavior of these depth profiles at varying infiltration times are qualitatively compared to various computed predictions and conclusions are drawn about the mechanisms of each of these processes. TMA infiltration into PMMA appears to transition from a diffusion-limited process at low temperatures (90 °C) to a reaction-limited process at high temperatures (135 °C) for the film thicknesses investigated here (200 nm). While TMA appears to fully infiltrate these 200 nm PMMA films within a few hours, TiCl 4 infiltration into PMMA is considerably slower, with full saturation not occurring even after 2 days of precursor exposure. Infiltration at 90 °C is so slow that no clear conclusions about mechanism can be drawn; however, at 135 °C, the TiCl 4 infiltration into PMMA is clearly a reaction-limited process, with TiCl 4 permeating the entire thickness (at low concentrations) within only a few minutes, but inorganic loading continuously increasing in a uniform manner over a course of 2 days. Near-surface deviations from the uniform-loading expected for a reaction-limited process also suggest that diffusional hindering is high for TiCl 4 infiltration into PMMA. In conclusion, these results demonstrate a new, ex situ analysis approach for investigating the rate-limiting process mechanisms for vapor phase infiltration.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Effect of Gd-doped ceria infiltration into Ni-YSZ on reversible solid oxide cell operation

Gadolinium doped ceria (GDC) infiltration into Ni-(Y 2 O 3 ) 0•08 (ZrO 2 ) 0.92 (Ni-YSZ) fuel electrodes has been shown to significantly improve solid oxide electrolysis cell performance and stability. However, the effects of GDC infiltration on cells operated reversibly between fuel cell and electrolysis modes have not been reported previously. Here we present reversible solid oxide cell life test results for different GDC infiltration loadings into Ni-YSZ electrodes in two types of fuel-electrode-supported solid oxide cells. Electrochemical impedance spectroscopy reveals that GDC infiltrant lowers the initial cell area specific resistance (ASR) and limits the degradation – for example, the GDC-infiltrated electrode ASR increased by 0.1 Ω cm 2 over 1000 h of reversible operation at ±0.5 A cm –2 and 800 °C, compared to 0.19 Ω cm 2 for non-infiltrated cells. Cell voltage degradation rates were reduced by infiltration during operation at a current density of ±0.5 A cm –2 at 800 °C, and during at 700 °C at ±0.75 A cm –2 . Furthermore, scanning electron microscopy observations show that the infiltrated GDC nanoparticles mitigate Ni particle coarsening in the Ni-YSZ electrode, possibly explaining the enhanced cell stability.

25 ENERGY STORAGE↗

DOE OSTI2024

Fluid-Driven Mass Transfer During Retrograde Metamorphism and Exhumation of the UHP Western Gneiss Region Terrane, Norway

Dehydration reactions within subducted oceanic crust are important for fluid-mediated element transfer within the subducting plate and potentially to the mantle wedge. The effects of metamorphic reactions and fluid flow on element recycling that occur during retrogression and exhumation of subducted continental crust from mantle depths are poorly understood. We study two metabasite pods with fresh eclogite cores and retrogressed amphibolite-facies rims and surrounding host gneiss within the Western Gneiss Region (WGR), Norway, to better understand element mobility and mass transfer during exhumation of subducted continental crust. Bulk-rock data were collected from samples taken across the pod and into the host gneiss. Phengite breakdown in eclogite and epidote recrystallization in veins and/or gneiss within pod cores contributed large ion lithophile elements and REE to retrogressed eclogite closest to the pod cores. In gneiss hosting the pods, phengite and epidote breakdown provided fluid that mediated elemental transfer and redistribution to the pod rim or tail. Compared to the studied pod in the southern WGR, the pod in the northern WGR underwent higher P-T conditions, partial melting and higher strain rates. This resulted in the infiltration of external fluid farther into the pod interior from the rim and facilitated larger mass gain in trace elements in the amphibolite tail of the pod relative to fresh eclogite in the core. The results show clear evidence for retrogression dehydration reactions driving significant fluid-mediated element redistribution as observed on the outcrop scale during exhumation following ultrahigh-pressure metamorphism, which directly impacts element signatures within the exhuming crust.

58 GEOSCIENCES↗

NASA NTRS1983

The desorptivity model of bulk soil-water evaporation

Available models of bulk evaporation from a bare-surfaced soil are difficult to apply to field conditions where evaporation is complicated by two main factors: rate-limiting climatic conditions and redistribution of soil moisture following infiltration. Both factors are included in the "desorptivity model', wherein the evaporation rate during the second stage (the soil-limiting stage) of evaporation is related to the desorptivity parameter, A. Analytical approximations for A are presented. The approximations are independent of the surface soil moisture. However, calculations using the approximations indicate that both soil texture and soil moisture content at depth significantly affect A. Because the moisture content at depth decreases in time during redistribution, it follows that the A parameter also changes with time. Consequently, a method to calculate a representative value of A was developed. When applied to field data, the desorptivity model estimated cumulative evaporation well. The model is easy to calculate, but its usefulness is limited because it requires an independent estimate of the time of transition between the first and second stages of evaporation. The model shows that bulk evaporation after the transition to the second stage is largely independent of climatic conditions.

Clapp, R. B.↗

DOE OSTI2023

Ethanol-fueled metal supported solid oxide fuel cells with a high entropy alloy internal reforming catalyst

High-performance metal supported solid oxide fuel cells (MS-SOFC) with an integrated high entropy alloy (HEA) internal reforming catalyst (IRC) are demonstrated for transportation applications using ethanol and methanol as fuels. Addition of the HEA IRC dramatically improves cell performance and stability when using ethanol/water blend fuel. Absence of carbon deposition predicted by thermodynamic calculations is confirmed by Raman spectroscopy analysis of posttest anodes. Optimal catalyst processing (deposition technique, loading, firing temperature) and cell operation conditions (flow rates, temperature, fuel compositions) are explored. Infiltrated HEA reforming catalyst provides a highly porous structure and low catalyst loading (6 mg cm –2 ). The designed structure and catalysts achieve small mass transport resistances in the fuel electrode (26.2 s m –1 ) and oxygen electrode (41.6 s m –1 ). The best ethanol concentration (60:40 v% ethanol: water) provides 0.83 W cm –1 at 700 °C, without carbon deposition. The ethanol-fueled MS-SOFC is operated for 500 h, including five thermal cycles. As a result, cell evolution is similar to that reported previously for hydrogen fuel; nickel aggregation and chromia deposition were the major observed changes, and carbon formation can be avoided even after long-term operation.

30 DIRECT ENERGY CONVERSION↗

NASA NTRS2000

Parametric Study of Reactive Melt Infiltration

Reactive melt infiltration is viewed as a promising means of achieving near-net shape manufacturing with quick processing time and at low cost. Since the reactants and products are, in general, of varying density, overall conservation of mass dictates that there is a force related to chemical conversion which can directly influence infiltration behavior. In effect, the driving pressure forces may compete with the forces from chemical conversion, affecting the advancement of the front. We have developed a two-dimensional numerical code to examine these effects, using reaction-formed silicon carbide as a model system for this process. We have examined a range of initial porosities, pore radii, and reaction rates in order to investigate their effects on infiltration dynamics.

Nelson, Emily S.↗

DOE OSTI2023

Impact of controlled prewetting on part formation in binder jet additive manufacturing

Binder jetting is an additive manufacturing process that bonds powder through selectively depositing binder by inkjet printing. The part is then extracted and densified by sintering and/or infiltration. The process offers low costs and fast build rates, but properties can be poor due to residual porosity after sintering. The inkjet printing process may contribute to this residual porosity by creating large pores. The droplet kinetic energy ejects some powder particles from the bed and rearranges others. Particle ejection and rearrangement are theorized to create porous regions in binder-jetted parts. In this work, small amounts of moisture are added to the spread powder before printing and the impact on part formation, part properties, and printing parameters measured with varied droplet spacing, droplet velocity, and print frequency. Moisture is added by applying an atomized fluid mixture to the powder between layer spreading and binder printing. The fluid mixture partially evaporates but leaves a stable residue to increase cohesion and enhance imbibition. Moisture addition to the powder increases the range of droplet spacings for line formation while reducing particle ejection, powder rearrangement, and balling in layer and multilayer parts. Excessive moisture addition decreases the effective saturation of printed lines, but saturation in 3D parts is less impacted. Increased surface roughness in the first few layers of a print was also mitigated with prewetting. Finally, high-speed X-ray imaging verified prewetting reduction in particle ejection and rearrangement.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Zinc treatment to enhance nickel electrode performance for liquid alkaline water electrolyzers

Raney Ni treatment is introduced to the surface of Ni mesh anode electrodes, enhancing liquid alkaline water electrolyzer performance. The surface of the Ni mesh is alloyed with Zn, deposited by either an aqueous infiltration of Zn salt or direct reaction with Zn foil. The extent of alloying is controlled by a heat treatment step. For both processes, fine porosity and enhanced surface area are obtained after leaching the Zn out of the surface alloy layer. The observed electrode surface structure and performance is quite sensitive to the thermal treatment temperature. The enhanced surface area improves full cell performance by 90 mV for infiltrated Zn treated at 600 °C and by 185 mV for Zn foil reacted at 425 °C (at 2 A cm −2 and 80 °C). In conclusion, the Zn treatment methods produce stable operating performance, exhibiting no decay after 150 h for the infiltrated Zn treated at 600 °C, and a decay rate of 4.6 μV h −1 over 100 h for the Zn foil reacted at 425 °C (at 1 A cm −2 and 80 °C).

LAWE↗

DOE OSTI2023

Energy Savings With Acceptable Indoor Air Quality Through Improved Airflow Control in Residential Retrofits

The Partnership for Advanced Residential Retrofit (PARR) has been a U.S. Department of Energy (DOE) Building America team since 2009, with a primary focus on upgrading the performance of existing buildings to reduce energy loads. In this project, PARR’s work explored the integration of airflow-focused measures in residential retrofit homes with the goal to maximize energy savings while ensuring acceptable indoor air quality (IAQ) using a systems approach to controlling four contributing air streams: • Building air leakage (natural, uncontrolled infiltration), • Forced-air distribution system static pressure and airflow rate, • Distribution system duct leakage, and • Mechanical ventilation. This project addressed airflows in houses, their combined impact on energy use and IAQ, and the comparative effects of typical insulation and air sealing practices versus integrated system-level retrofits. Additionally, practical considerations for contractors taking either approach were addressed. Finally, the effects of supply ventilation and exhaust ventilation on IAQ were compared in occupied homes.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRSDate not supplied

Modeled Impacts of LULC and Climate Change Predictions on Water Quality in Belize

Land use and land cover (LULC) change can have detrimental effects on water quality. In Belize, agricultural expansion creates the risk of increased sediment load and excess nutrients in runoff water, while deforestation removes potential infiltration sites for this outflow. Climate change and evolving precipitation rates can intensify the quantity of runoff, further enabling the flow of sediments and excess nutrients out to the lagoon surrounding the Belize Barrier Reef Reserve System (BBRRS). This study estimated future water quality in Belize by projecting LULC change through 2090 across Belize’s major watersheds based on observed trends from 2008-2018. Those LULC projections were subsequently combined with soil type data, elevation, and precipitation rates into a hydrologic model to produce runoff estimates as a proxy for water quality. The two Coupled Model Intercomparison Project phase 6 (CMIP-6) scenarios employed in the study represented bookend climate change scenarios, and both predicted lower precipitation rates in Belize over the next century due to climate change. When holding LULC change constant, these climate scenarios projected a decrease in runoff, suggesting a positive relationship between precipitation and runoff. The southern watersheds in particular are projected to experience greater decreases in annual rainfall and runoff by 2090. When holding climate constant, runoff increased by approximately 2.8% in the Conservation-focused LULC scenario by 2090, which was 28% lower than the Business as Usual scenario and 42% lower than the Development scenario.

water resources↗

DOE OSTI2025

Prototype Hanford Barrier Performance Monitoring Report: Fiscal Year 2024

This report provides an annual update on performance monitoring of the Prototype Hanford Barrier (PHB) at the Hanford Site. The PHB is part of a long-term study that serves as the scientific basis for many of the evapotranspiration-capillary barrier designs currently used globally and for future engineered barrier designs planned for remedial actions over waste and demolition sites at the Hanford Site. The PHB allows us to identify potential future issues and develop better monitoring techniques before these engineered barriers are constructed. Surface barriers like the PHB are essential for preventing water infiltration and curbing the spread of contaminants to groundwater. Effective monitoring of soil moisture levels above and below these barriers is crucial given that performance metrics could span up to 1,000 years. From July 2023 to June 2024, the water flux (as measured by tipping buckets) through the 2-m-thick silt loam layer of the PHB – a fine silty material that stores water under high capillary tension – remained well below the 0.5-mm-per-year performance threshold, demonstrating its effectiveness in preventing water penetration. In 2024, degraded tipping bucket gauges were replaced to ensure the accuracy of future data. Additionally, neutron probes revealed that the wetting front from the rainy season only penetrated to a maximum depth of 1.2 m into the silt loam. This further demonstrated the barrier's efficiency, as the wetting front did not fully penetrate the 2-m-thick capillary barrier. The western gravel slope of the PHB, composed of Hanford Site pit gravel of varying sizes, demonstrated low flux rates. In contrast, the eastern riprap slope exhibited higher flux rates. Zhang (2017) found that the riprap side slope of the PHB had the highest drainage rates in January and the lowest in late summer or early fall, indicating significant summer evaporation. Drainage rates increased significantly under enhanced precipitation conditions, far exceeding the design criterion, which could lead to water infiltration into the waste zone. The study introduced the “edge effect,” where elevated drainage rates from the riprap may migrate laterally beneath the barrier, compromising its ability to isolate waste, and recommended expanding the barrier and conducting further research to mitigate this issue. This report provides a review on surface barrier edge effects and their potential impact to subsurface contaminant migration.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

NASA NTRS1993

Verification of a two-dimensional infiltration model for the resin transfer molding process

A two-dimensional finite element model for the infiltration of a dry textile preform by an injected resin was verified. The model, which is based on the finite element/control volume technique, determines the total infiltration time and the pressure increase at the mold inlet associated with the RTM process. Important input data for the model are the compaction and permeability behavior of the preform along with the kinetic and rheological behavior of the resin. The compaction behavior for several textile preforms was determined by experimental methods. A power law regression model was used to relate fiber volume fraction to the applied compaction pressure. Results showed a large increase in fiber volume fraction with the initial application of pressure. However, as the maximum fiber volume fraction was approached, the amount of compaction pressure required to decrease the porosity of the preform rapidly increased. Similarly, a power law regression model was used to relate permeability to the fiber volume fraction of the preform. Two methods were used to measure the permeability of the textile preform. The first, known as the steady state method, measures the permeability of a saturated preform under constant flow rate conditions. The second, denoted the advancing front method, determines the permeability of a dry preform to an infiltrating fluid. Water, corn oil, and an epoxy resin, Epon 815, were used to determine the effect of fluid type and viscosity on the steady state permeability behavior of the preform. Permeability values measured with the different fluids showed that fluid viscosity had no influence on the permeability behavior of 162 E-glass and TTI IM7/8HS preforms. Permeabilities measured from steady state and advancing front experiments for the warp direction of 162 E-glass fabric were similar. This behavior was noticed for tests conducted with corn oil and Epon 815. Comparable behavior was observed for the warp direction of the TTI IM7/8HS preform and corn oil. Mold filling and flow visualization experiments were performed to verify the analytical computer model. Frequency dependent electromagnetic sensors were used to monitor the resin flow front as a function of time. For the flow visualization tests, a video camera and high resolution tape recorder were used to record the experimental flow fronts. Comparisons between experimental and model predicted flow fronts agreed well for all tests. For the mold filling tests conducted at constant flow rate injection, the model was able to accurately predict the pressure increase at the mold inlet during the infiltration process. A kinetics model developed to predict the degree of cure as a function of time for the injected resin accurately calculated the increase in the degree of cure during the subsequent cure cycle.

Hammond, Vincent H.↗

NASA NTRS2007

Rapid Fabrication of Carbide Matrix/Carbon Fiber Composites

Composites of zirconium carbide matrix material reinforced with carbon fibers can be fabricated relatively rapidly in a process that includes a melt infiltration step. Heretofore, these and other ceramic matrix composites have been made in a chemical vapor infiltration (CVI) process that takes months. The finished products of the CVI process are highly porous and cannot withstand temperatures above 3,000 F (approx.1,600 C). In contrast, the melt-infiltration-based process takes only a few days, and the composite products are more nearly fully dense and have withstood temperatures as high as 4,350 F (approx.2,400 C) in a highly oxidizing thrust chamber environment. Moreover, because the melt- infiltration-based process takes much less time, the finished products are expected to cost much less. Fabrication begins with the preparation of a carbon fiber preform that, typically, is of the size and shape of a part to be fabricated. By use of low-temperature ultraviolet-enhanced chemical vapor deposition, the carbon fibers in the preform are coated with one or more interfacial material(s), which could include oxides. The interfacial material helps to protect the fibers against chemical attack during the remainder of the fabrication process and against oxidation during subsequent use; it also enables slippage between the fibers and the matrix material, thereby helping to deflect cracks and distribute loads. Once the fibers have been coated with the interfacial material, the fiber preform is further infiltrated with a controlled amount of additional carbon, which serves as a reactant for the formation of the carbide matrix material. The next step is melt infiltration. The preform is exposed to molten zirconium, which wicks into the preform, drawn by capillary action. The molten metal fills most of the interstices of the preform and reacts with the added carbon to form the zirconium carbide matrix material. The zirconium does not react with the underlying fibers because they are protected by the interfacial material(s). The success of the melt-infiltration step depends on interface material selection and uniform coating of the fibers, infiltration with the correct amount of carbon, and careful control of temperature and rate of heating.

Williams, Brian E.↗

NASA NTRS2006

Carbon Nanotube-enhanced Carbon-phenolic Ablator Material

Phenolic impregnated carbon ablator (PICA) is a thermal protection system (TPS) material developed at NASA Ames Research Center in the mid-90 s for Discovery missions. It was used on the Stardust return capsule heat shield which successfully executed the highest speed Earth entry to date on January 15, 2006. PICA is a porous fibrous carbon insulation infiltrated with phenolic resin, and is an excellent ablator that is effective for heating rates up to 1000 W/sq cm. It is one of several candidate TPS materials for the next generation of crewed spacecraft for Lunar and Mars missions. We will describe an ongoing research effort at NASA to improve mechanical properties of the phenolic matrix with carbon nanotubes. The aim is two-fold: to increase overall TPS strength during reentry and to improve Micrometeoroid/Orbital Debris (MMOD) protection in space. The former requires at least a good dispersion of nanotubes in phenolic, while the latter also requires covalent bonding between them to couple and transfer impact energy effectively from matrix to nanotubes. We will discuss the required chemical functionalization of nanotubes, processing issues and test results.

Nikolaev, P.↗

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↗