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At least 469 records · Page 26

Oriented porous LLZO 3D structures obtained by freeze casting for battery applications

All solid-state lithium batteries are, potentially, higher energy density and safer alternatives to conventional lithium-ion batteries (LIBs). These are particularly attractive characteristics for large-scale applications such as electric vehicles and grid energy storage systems. However, the thin film deposition techniques used to make current devices are not readily scalable, and result in low areal capacities, which translate to low practical energy densities. To overcome these deficiencies, it is necessary to design thicker electrodes similar to what are used in LIBs (30–100 μm), in which the active material is composited with an ionic conductor and an electronically conducting additive, to overcome transport limitations. In this paper, we propose a method for making such an electrode, starting with a porous scaffold, i.e. Li 7 La 3 Zr 2 O 12 (LLZO), made by freeze casting, which is then infiltrated with the active material LiNi 0.6 Mn 0.2 Co 0.2 O 2 (NMC-622) and other components. The freeze casting technique results in the formation of oriented channels with low tortuosity, which run roughly parallel to the direction of the current. The scaffolds were characterized with synchrotron X-ray micro-tomography for structural analysis, as well as synchrotron X-ray fluorescence to map the elemental distribution in the infiltrated composite. A hybrid half-cell was constructed and cycled as proof of principle, and it showed good stability. In addition, a bilayer structure consisting of a porous layer combined with a dense LLZO film was successfully made as a prototype of an all solid-state battery. Finally, a mathematical model was established to propose optimized scaffold structures for battery performance.

25 ENERGY STORAGE↗

A study of the micro- and nanoscale deformation behavior of individual austenitic dendrites in a FeCrMoVC cast alloy using micro- and nanoindentation experiments

Micro- and nanoindentation experiments were conducted to investigate the deformation mechanisms in a Fe79.4Cr13Mo5V1C1.6 (wt. %) cast alloy. This alloy consists of an as cast microstructure mainly composed of austenite, martensite, and a complex carbide network. During microhardness testing, metastable austenite transforms partially into martensite confirmed by electron backscatter diffraction. For nanoindentation tests, two different indenter geometries were applied (Berkovich and cube corner type). Load-displacement curves of nanoindentation in austenitic dendrites depicted pop-ins after transition into plastic deformation for both nanoindenters. Characterizations of the region beneath a nanoindent by transmission electron microscopy revealed a martensitic transformation as an activated deformation mechanism and suggest a correlation with the pop-in phenomena of the load-displacement curves. Furthermore, due to an inhomogeneous chemical composition within the austenitic dendrites, more stabilized regions deform by mechanical twinning. This additional deformation mechanism was only observed for the cube corner indenter with the sharper geometry since higher shear stresses are induced beneath the contact area.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

Optically pumped lasing in single crystals of organometal halide perovskites prepared by cast-capping method

A simple “cast-capping” method is adopted to prepare single-crystal perovskites of methyl ammonium lead bromide (CH{sub 3}NH{sub 3}PbBr{sub 3}). By capping a CH{sub 3}NH{sub 3}PbBr{sub 3} solution casted on one substrate with another substrate such as glass, mica, and distributed Bragg reflector (DBR), the slow evaporation of solvent enables large-size cubic crystals to grow between the two substrates. Under optical pumping, edge-emitting lasing is observed based on Fabry–Pérot resonation between parallel side facets of a strip-shaped crystal typically with a lateral cavity length of a few tens of μm. On the other hand, vertical-cavity surface-emitting lasing (VCSEL) is obtained from a planar crystal grown between two DBRs with a cavity thickness of a few μm. Simultaneous detection of those edge- and surface-emissions reveals that the threshold excitation fluence of VCSEL is higher than that of the edge-emitting lasing due to thickness gradient in the planar crystal.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

Path length dependent neutron diffraction peak shifts observed during residual strain measurements in U–8 wt% Mo castings

This study reports an angular diffraction peak shift that scales linearly with the neutron beam path length traveled through a diffracting sample. This shift was observed in the context of mapping the residual stress state of a large U–8 wt% Mo casting, as well as during complementary measurements on a smaller casting of the same material. If uncorrected, this peak shift implies a non-physical level of residual stress. A hypothesis for the origin of this shift is presented, based upon non-ideal focusing of the neutron monochromator in combination with changes to the wavelength distribution reaching the detector due to factors such as attenuation. The magnitude of the shift is observed to vary linearly with the width of the diffraction peak reaching the detector. Consideration of this shift will be important for strain measurements requiring long path lengths through samples with significant attenuation. This effect can probably be reduced by selecting smaller voxel slit widths.

36 MATERIALS SCIENCE↗

Investigations Towards Ultra-Low Cost Nb 3 Sn SRF Fabrication via Melt Casted Bronze Route Processing

Here, a novel approach to fabricating Nb 3 Sn SRF cavities and other RF components using an ultra-low-cost melt casting fabrication process has been investigated. This simple, low cost melt casting technique has the potential to be used to fabricate nearly any superconducting Nb3Sn structure using either the Bronze Route (BR), Internal Tin (IT), External Tin (ET) processes as well as normal conducting pure copper (Cu) cavities. Most of the heat treated samples that were examined using SEM/EDX seemed to show a reasonable correlation of T c onset and transition width (ΔT c ) of the ingots initial/starting Sn content to the desired stoichiometric Nb 3 Sn phase, where the lower starting Sn content coupons resulted in lower T c 's with broader transition widths and the higher starting Sn coupons resulted in higher T c 's with narrower ΔT c ’s. The best samples had T c onsets ~17-18 K and ΔT c 's < 2 K. Two samples were further tested for RF surface resistance (R s ) and Quality Factor (Q) at JLAB. Here, these RF measurements were performed at 7.4 GHz using a calorimetric technique and showed two transitions, one at ~ 8 K and another at ~ 14 K; values of R s were at least two orders of magnitude higher than similar high quality Nb 3 Sn films directly deposited substrates by JLAB and with another superconducting transition close to the superconducting transition temperature of niobium. Substantial improvements in the processing variables ranging from higher quality of the initial ingots with higher Sn content, to better electropolishing and reaction heat treatment regimens will be necessary to realize improved RF performance metrics.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

Freeze-cast yttria-stabilized zirconia pore networks: Effects of alcohol additives

Freeze casting yttria-stabilized zirconia (YSZ) can be useful in making electrodes for solid oxide fuel cells (SOFCs) by introducing hierarchical porosity to increase triple-phase boundary (TPB) area while maintaining adequate fuel flow. Here, in this work, the influence of alcohol additives on pore structure of aqueous YSZ freeze-cast samples was investigated. Slurries with ethanol, iso-propyl alcohol, or methanol as additives were compared to a control sample. Pore characteristics along sample lengths were measured using X-ray computed tomography reconstructions. The control sample showed significant changes in pore size along sample length, whereas pore size of the alcohol additive samples remained similar, indicating that freezing rates of the additive samples remained constant during solidification. Finally, ice lens formation and interactions between alcohols and slurry functional additives (dispersant, surfactant, and binder) resulted in complex pore structures which show promise in increasing SOFC TPB area.

36 MATERIALS SCIENCE↗

Physical vapor deposition simulator by graphical processor unit ray casting

This paper presents fast, accurate software for modeling physical vapor deposition systems over irregular surfaces. The model is implemented using graphics processing unit (GPU) ray casting. Applied models are viewed as a cross section of the area of interest. Given evaporation rate, time, and angular profiles in a vacuum system, an iterative time-step approach for calculating deposition profiles is calculated in the GPU architecture following a ballistic modeling approach. Thin-film technologies for the electronics industry will require evaporations on complex surfaces. Depending on the nature of the surface, a uniform thin film across the topology is wanted for various device parameters. The ray casting method is tested against various profiles. The code is freely distributed on GitHub (see https://github.com/adam-r-thomas/PVDS).

Engineering↗

Pioneering Microporous Layers for Proton-Exchange-Membrane Water Electrolyzers via Tape Casting

The imperative shift towards decarbonization necessitates the production of clean hydrogen through water electrolysis, powered by renewable energy sources. Among electrolyzer technologies, proton-exchange-membrane (PEM) systems emerge as a promising option for large-scale hydrogen generation due to their modular design and rapid response, aligning well with the intermittency of renewable energy. In this study, we employ a tape casting method to fabricate microporous layers (MPLs), both as a single layer and as a bilayer over commercial porous transport layers (PTLs), to further enhance performance of water electrolyzers. We demonstrate that microporous layers require adequate pore sizes to facilitate gas removal, preventing gas flooding and preserving electrolyzer performance. Our single layer microporous layers exhibit lower overpotentials compared to commercial sintered Ti PTLs by 142 mV at 4 A·cm ⁻2 . Moreover, we show that having an effective microporous layer enhances electrolyzer performance irrespective of the substrate used, offering avenues for cost reduction. We also investigate novel PTL structures with reduced tortuosity and integrated MPL fabricated via phase inversion tape casting, resulting in a performance enhancement of 92 mV. Our findings unravel the critical role of microporous layer structures and their impact on electrolyzer performance.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Interrelationship of Thermal Effects on Calcium Sulfate Dihydrate Casts Containing Borax and Kaolin: Differential Thermal Analysis (DTA), Thermogravimetric Analysis (TGA), and Contact Dilatometry

The core composition of gypsum wallboard is calcium sulfate dihydrate (CaSO 4 ·2H 2 O) with varying impurities, additives, or both. This study compares here two commercially calcined sources of hemihydrate (CaSO 4 ·½H 2 O) from a natural source and a synthetic by-product of flue gas desulfurization and neutralization to reagent grade hemihydrate. Two common ingredients, borax and kaolin, are mixed into a slurry with distilled water. The analysis supports the hypothesis that minor components in the cast have an effect on the high temperature performance of gypsum casts. The analysis is enhanced when the differential thermal analysis, thermogravimetric analysis, and dilatometry data are combined to study the changes in density versus heat flow. Specifically, the thermal performance is affected by (1) the impurities found in hemihydrate sources; (2) during the fluidization phase, the reaction of borax with free Ca ++ ions to form new borate salts that melt at lower temperatures; and (3) the intercalation of these and other ions with kaolin, providing thermal stability by reducing the formation of thermally active salts.

36 MATERIALS SCIENCE↗

Effect of additives on carbon dioxide uptake and compressive strength of dry-cast concrete

The main thrust of the work reported herein is to study the effect of chemical additives to make beneficial use of carbon dioxide in enhancing the compressive strength of dry-cast concrete. The additives used in this investigation were calcium and magnesium oxides and silicates, nickel oxide, sodium hydroxide, sodium bicarbonate and strontium chloride. The experimental results showed that both the carbonation reactions and the compressive strength of dry-cast concrete mixtures were improved when using chemical additives. Experimental investigations for optimisation were also undertaken with selected additives to further increase the carbon dioxide uptake and improve the compressive strength. The best results were obtained when using calcium silicate in combination with calcium oxide. The early-age compressive strength of specimens made from the optimised mixture increased from 9·82 MPa to 13·32 MPa, and the specimens’ carbon dioxide uptake increased from 8·76% to 10·62% of cement weight.

Construction & Building Technology↗

Composition Driven, Statistical Review of Cast Stone Screening Matrix Results

Recent studies in support of Cast Stone development for the Hanford Site were designed to screen the effects of mix components on properties and performance of the waste form. Dry blend components, including portland cement, blast furnace slag, and Class F fly ash, sourced from both southeastern and northwestern suppliers, were included in the screening matrix. Multiple decontaminated salt solutions (simulated) were combined with the dry blend components at various liquid to solid ratios following a statistically designed matrix of compositions. Properties of the resulting mixes and performance of the cured materials were then measured and related to the dry blend components and salt solutions that were used for each mix. At the conclusion of the screening matrix work, SRNL felt that additional insight into the study might be obtained by relating the properties and performance of the materials to the composition of each Cast Stone mix, as opposed to just the dry blend – salt solution combination. This memorandum provides the results of a statistically driven review of the screening matrix data as a function of the composition of each mix. It is meant to augment the results obtained by reviewing the screening matrix data as a function of the dry blend and salt solution combination.

Edwards, T. B.↗

Technetium and Iodine Getters to Improve Cast Stone Performance

To determine the effectiveness of the various getter materials prior to their solidification in Cast Stone, a series of batch sorption experiments was performed at Pacific Northwest National Laboratory. To quantify the effectiveness of the removal of Tc(VII) and I(I) from solution by getters, the distribution coefficient, K d (mL/g), was calculated. Testing involved placing getter material in contact with spiked waste solutions at a 1:100 solid-to-solution ratio for periods up to 45 days with periodic solution sampling. One Tc getter was also tested at a 1:10 solid-to-solution ratio. Two different solution media, 18.2 MΩ deionized water (DI H 2 O) and a 7.8 M Na LAW simulant, were used in the batch sorption tests. Each test was conducted at room temperature in an anoxic chamber containing N2 with a small amount of H 2 (0.7%) to maintain anoxic conditions. Each getter-solution combination was run in duplicate. Three Tc- and I-doping concentrations were used separately in aliquots of both the 18.2 MΩ DI H2O and a 7.8 M Na LAW waste simulant. The 1× concentration was developed based on Hanford Tank Waste Operations Simulator (HTWOS) model runs to support the River Protection Project System Plan Revision 6. The other two concentrations were 5× and 10× of the HTWOS values. The Tc and I tests were run separately (i.e., the solutions did not contain both solutes). Sampling of the solid-solution mixtures occurred nominally after 0.2, 1, 3, 6, 9, 12, 15 days and ~35 to 45 days. Seven getter materials were tested for Tc and five materials were tested for I. The seven Tc getters were blast furnace slag 1 (BFS1) (northwest source), BFS2 (southeast source), Sn(II)-treated apatite, Sn(II) chloride, nano tin phosphate, KMS (a potassium-metal-sulfide), and tin hydroxapatite. The five iodine getters were layered bismuth hydroxide (LBH), argentite mineral, synthetic argentite, silver-treated carbon, and silver-treated zeolite. The Tc Kd values measured from experiments conducted using the 7.8 M Na LAW simulant (the simulant selected to represent LAW) for the first 15 days for four Tc getters (BFS1, BFS2, Sn(II)-treated apatite, and Sn(II) chloride) show no, to a very small, capacity to remove Tc from the LAW simulant. For the Tc-getter experiments in the 7.8 M LAW simulant, the majority of the effluent samples show very small drops in Tc concentrations for the 35-day compared to the 15-day samplings. However, the Tc concentration in the simulant blanks also dropped slightly during this period, so the effect of the getter contacting LAW simulant at 35 days compared to 15 days is minimal; except that the BFS1 1:10 test shows a slow but steady decrease in Tc concentration in the LAW simulant supernatant from the beginning to the 35 day contact at which point about 20% of the original Tc has been removed from solution. Lastly, the KMS getter gives the highest K d value for Tc at 35 days where K d values have increased to 104 mL/g. When considering the different I getters reacting with the 7.8 M LAW simulant, two getters are much more effective than the others: Ag zeolite and Syn Arg. The other getters have calculated iodide distribution coefficients that show very limited effectiveness in the caustic conditions created by the LAW simulant. These are preliminary results that will need more detailed analyses including both pre- and post-batch sorption getter solid-phase characterization using state-of-the-art instrumentation such as synchrotron X-ray absorption spectroscopy, which can delineate the oxidation state of the Tc and likely iodine species as well as some of the getters key major components, sulfur and iron in the BFS, and tin and sulfur in the tin-bearing and sulfur-bearing getters. This report also describes future experimental studies to be performed to better elucidate the mechanisms controlling the Tc and I sequestration processes in the various getters and leach tests of getter-bearing Cast Stone monoliths.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Interim Report on Mixing During the Casting of LEU-10Mo Plates in the Triple Plate Molds

LEU-10%Mo castings are commonly produced by down blending unalloyed HEU with a DU-12.7%Mo master-alloy. This work uses process modeling to provide insight into the mixing of the unalloyed uranium and U-Mo master alloy during melting and mold filling of a triple plate casting. Two different sets of situations are considered: (1) mixing during mold filling from a compositionally stratified crucible and (2) convective mixing of a compositionally stratified crucible during mold heating. The mold filling simulations are performed on the original Y-12 triple plate mold and the horizontal triple plate mold.

36 MATERIALS SCIENCE↗

Technetium, Iodine, and Chromium Adsorption/Desorption Kd Values for Vadose Zone Pore Water, ILAW Glass, and Cast Stone Leachates Contacting an IDF Sand Sequence

Performance and risk assessments of immobilized low-activity waste (ILAW) at the Integrated Disposal Facility (IDF) have shown that risks to groundwater are quite sensitive to adsorption-desorption interactions occurring in the near- and far-field environment. These interactions between the underlying sediments and the contaminants present in the leachates that descend from the buried glass, secondary waste grouts, and potentially Cast Stone low-activity waste packages have been represented in these assessments using the contaminant distribution coefficient (Kd) construct. Some contaminants (99Tc, 129I, and Cr) present in significant quantities in these wastes have low Kd values and tend to drive risk to public health and the environment. Relatively small changes in the Kd value can cause relatively large changes in the retardation factor. Thus, even relatively small uncertainty in the Kd value can result in a relatively large uncertainty in the risk determined through performance assessment modeling. The purpose of this study is to further reduce the uncertainty in Kd values for 99Tc, iodine (iodide and iodate), and Cr (chromate; CrO42-) by conducting systematic adsorption-desorption experiments using actual sand-dominated Hanford formation sediments from beneath the IDF and solutions that closely mimic Hanford vadose zone pore water and leachates from Cast Stone and ILAW glass waste forms. Twenty-four batch and 21 flow-through column experiments were conducted, yielding 261 Kd measurements for these key contaminants, and contributing to our understanding for predicting transport from wastes disposed to the IDF. While the batch Kd methodology is not well-suited for measuring Kd values for non-sorbing species (as noted by the U.S. Environmental Protection Agency), the batch Kd results presented here are not wholly inconsistent with the column Kd results, and could be used for sensitivity purposes. Results from the column experiments are consistent with the best estimate and lower range of Kd values reported by Krupka et al. and Cantrell et al.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DE-NE0000724 - Research Performance Final Report - Investigation of Thermal Aging Effects on the Evolution of Microstructure and Mechanical Properties of Cast Duplex Stainless Steels

This report details the research activities carried out under DOE-NEUP award number DE-NE0000724 concerning the evolution of structural and mechanical properties during thermal aging of CF–3 and CF–8 cast duplex stainless steels (CDSS). The overall objective of this project was to use state-of-the-art characterization techniques to elucidate trends and phenomena in the mechanical and structural evolution of cast duplex stainless steels (CDSS) during thermal aging. These steels are commonly used as structural materials in commercial light water nuclear power plants, undergoing aging for decades in operation as cooling water pipes, pump casings, valve bodies, etc. During extended exposure to these conditions, CDSS are known to undergo a change in mechanical properties resulting in a loss of ductility, i.e. embrittlement. While it is generally accepted that structural changes within the ferrite phase, such as decomposition into iron (Fe)-rich and chromium (Cr)-rich domains, lead to the bulk embrittlement of the steels, many questions remain as to the mechanisms of embrittlement at multiple length scales. This work is intended to shed insight into the atomic level composition changes, associated kinetic mechanisms, and effects of changing phase structure on micro- and nano-scale deformation that lead to loss of impact toughness and tensile ductility in these steels. In general, this project provides a route to answer some of these major questions using techniques such as 3-dimensional (3-D) atom probe tomography (APT) and real-microstructure finite element method (FEM) modeling, which were not readily available when these steels were originally selected for service in light water reactors. Mechanical properties evaluated by Charpy V-notch impact testing (CVN), tensile testing, and microhardness and nanohardness measurements were obtained for each condition and compared with the initial baseline properties to view trends in deformation behavior during aging. Concurrent analysis of the microstructure and nanostructure by atom probe tomography (APT) and transmission electron microscopy (TEM) provide mechanistic insight into the kinetic and mechanical behavior occurring on the nano-scale. The presence and morphology of the ferrite, austenite, and carbide phases have been characterized, and formation of new phases during aging, including spinodal decomposition products (α- and α'-ferrite) and G-phase, have been observed. The mechanical and structural characterization have been used to create accurate FEM models based on the real micro- and nano-structures of the systems. These models provide new insight into the local deformation behavior of these steels and the effects of each individual phase (including ferrite, austenite, carbides, and spinodal decomposition products) on the evolving bulk mechanical behavior of the system. The project was divided into three major tasks: 1. Initial Microstructure and Mechanical Property Survey and Initiate Heat Treatment; 2. Microstructural Characterization and Mechanical Property Testing During Aging; and 3. Microstructure-based Finite Element Modeling. Each of these tasks was successfully executed, resulting in reliable data and analysis that add to the overall body of work on the CDSS materials. Baseline properties and aging trends in mechanical data confirm prior observations and add new insights into the mechanical behavior of the steels. Structural characterization on multiple length scales provides new information on phase changes occurring during aging and sheds light on the kinetic processes occurring at the atomic scale. Furthermore, a combination of mechanical testing and microstructural characterization techniques was utilized to design FEM models of local deformation behavior of the ferrite and austenite phases, providing valuable new information regarding the effects of each of the microstructural components on the hardening and embrittlement processes. The data and analysis presented in this report and the publication associated with this project (§V) increase the understanding of aging and deformation in CF–3 and CF–8 steels. These results provide valuable information that can be utilized to aid in making informed decisions regarding the ongoing use of these steels in commercial nuclear infrastructure.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

MLEP-Fail calibration for 1/8 inch thick cast plate of 17-4 steel.

The purpose of the work presented in this memo was to calibrate the Sierra material model Multilinear Elastic-Plastic Hardening Model with Failure (MLEP-Fail) for 1/8 inch thick cast plate of 17-4 steel. The calibration approach is essentially the same as that recently used in a previous memo using data from smooth and notched tensile specimens. The notched specimens were manufactured with three notch radii R = 1=8, 1/32 and 1/64 inches. The dimensions of the smooth and notched specimens are given in the prints in Appendix A. Two cast plates, Plate 3 and Plate 4, with nominally identical properties were considered.

42 ENGINEERING↗

ICME Guided Development of Advanced Cast Aluminum Alloys for Automotive Engine Applications (ADAPA)

Project Objectives: To develop a new class of advanced, cost competitive aluminum casting alloys providing a 25% improvement in component strength relative to components made with A319 or A356 alloys using sand and semi-permanent casting processes for high-performance engine applications. To demonstrate the power of Integrated Computational Materials Engineering (ICME) tools for accelerating the development of new materials and processing techniques, as well as to identify the gaps in ICME capabilities. To develop comprehensive cost models to ensure that components manufactured with these new alloys do not exceed 110% of the cost using incumbents alloys A319 or A356. To develop a technology transfer and commercialization plan for deployment of these new alloys in automotive engine applications. The key targets and baseline are shown in the table below.

36 MATERIALS SCIENCE↗

Casting of Reinforced Concrete Beam: Project Progress

Aging concrete structures in nuclear power plants undergo mechanical, physical, chemical, and radioactive degradation. One of the chemical degradation mechanisms that is investigated in the research project under the Plant Modernization Pathway of the Light Water Reactor Sustainability Program is the alkali-silica reaction (ASR). The ASR is a chemical process that over time, causes expansion of calcium silicate hydrate gel. To date, the research project has studied the ASR gel formation and expansion in non-reinforced concrete specimens using vibro-acoustic modulation (VAM) technique. However, nuclear plant concrete structures are reinforced, and it might influence the application of VAM technique on reinforced concrete specimens compared to non-reinforced specimens. A research activity is initiated between Idaho National Laboratory, Vanderbilt University, and University of Nebraska - Lincoln to study the impact of reinforcement in concrete structures on the application of the VAM technique. To support this activity, University of Nebraska - Lincoln is casting and curing four reinforced concrete samples that at the end of the curing period will be transferred to Vanderbilt University to perform experimental VAM study. Vanderbilt University and Idaho National Laboratory will perform the data analysis and enhance the developed structural health monitoring framework. In this report, a progress on casting and curing of reinforced concrete samples at University of Nebraska – Lincoln is provided.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗