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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Hybrid Ceramic-CMC Vane with EBC for Future Coal Derived Syngas Fired 65% Efficient Turbine Combined Cycle

The efficiency of both simple cycle and combined cycle power generation systems scale with the peak temperature at which the gas exits the combustor to drive the turbine. In conventional systems, a substantial fraction of the total turbine core flow exiting the compressor is diverted downstream to cool metallic turbine hardware rather than power the turbine, much of which is used to cool the first-stage turbine vane. The use of coal derived syngas fuels provides an additional challenge to the lifetime of materials utilized in the turbine, as particulate byproducts created in the coal gasification process melt in the combustion gas, and can subsequently deposit and interact with the turbine hardware. The development of durable hot-section materials capable of operating at temperature well above that of single crystal superalloy airfoil/zirconia based thermal barrier coatings is critical to realizing 65% efficient coal derived syngas fired gas turbine based power systems. To enable higher turbine inlet temperatures while lowering cooling air requirements, United Technologies Research Center (UTRC), the central R&D laboratory supporting UT Pratt & Whitney, led the conceptual design of a new type of ceramic composite turbine hot section materials system. The design focused on a novel hybrid monolithic ceramic-fiber reinforced ceramic matrix composite (CMC) first stage turbine vane having an environmental barrier coating. By utilizing ceramic construction in the turbine hot-section, the core flow normally used to cool metallic components will be substantially reduced, increasing efficiency and reducing emissions. To provide the framework for future demonstration testing, UTRC partnered with University of North Dakota Energy and Environmental Research Center (UNDEERC) to provide a conceptual design for a gasified coal fed high-pressure turbine combustor system designed to mimic the conditions expected in a future 65% fuel to busbar efficient syngas fueled gas turbine based combined cycle. The UNDEERC and UTRC collaborated on characterizing dusts from coal gasifier filtration systems.

10 SYNTHETIC FUELS↗
DOE OSTI2020

Technical Qualification of New Materials for High Efficiency Coal-Fired Boilers and Other Advanced FE Concepts: Haynes® 282® ASME Boiler and Pressure Vessel Code Case

This DOE Fossil Energy project, FEAA117, addressed materials issues relevant to qualifying and deploying a Ni-base alloy for a new application in an advanced ultra-supercritical coal-fired boiler. The goal was the deployment of Haynes International alloy Haynes® 282® for applications in superheaters, reheaters, and steam delivery pipes, by completing base metal, cross-weld and all-weld metal mechanical testing needed for an ASME Boiler and Pressure Vessel Code Case and the associated microstructural analyses needed for assurance of boiler-relevant lifetimes. The alloy also is of interest for other applications including supercritical CO₂ power generation cycles. Tensile testing was completed from 20°-927°C on the three base metal alloy 282 heats, two sets of cross-weld specimens and all weld metal specimens. A total of 148 creep tests with over 565,000 h of cumulative testing was completed on base metal, cross-weld and all weld metal specimens. This project was performed with cost share from Haynes International.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2024

Leveraging Additive Manufacturing and Coatings for Turbine Thermal Management

This presentation provides an update to the University Turbine Systems Research meeting on research performed at NETL in areas of sCO2 heat transfer for direct cycle power generation and aerothermal research to improve the efficiency and reduce emissions of small gas turbines. Specific topics include a novel test approach to measure the performance of a thermal barrier coating in-situ and fabrication of advanced, additively manufactured airfoils for testing in a high speed cascade.

Searle, Matthew↗
DOE OSTI2026

Operational Parameter Database for Molten Salt Thermal Energy Storage Tank Modeling

The second generation of concentrated solar power (CSP) plants is characterized by the use of a central receiver (either cavity or external), two molten nitrate salt tanks (60 wt.% NaNO 3 and 40 wt.% KNO 3 ), and a steam Rankine power-generation cycle connected through a primary heat exchanger. Molten salt thermal energy storage (TES) tanks have been widely deployed in commercial CSP plants worldwide and have been essential for increasing plant dispatchability and capacity factor, while also reducing the levelized cost of electricity (LCOE). These systems enable energy storage at the gigawatt-hour scale, typically providing 6 to 17 hours of storage duration. Despite being a commercial technology, the multiple failures observed after only a few months or years of operation in plants around the world demonstrate the technology's relative infancy and highlight the need for further research to improve its reliability. The National Laboratory of the Rockies (NLR), in collaboration with industry partners and academic and research institutions, has been leading multiple projects funded by the U.S. Department of Energy (DOE). These projects focus on addressing molten salt tank failures by improving tank design and welding fabrication practices, evaluating new alloys and weld fillers, and providing guidelines for tank commissioning and safe operation. In particular, this report presents modeling results on the effect of key tank operation parameters during 60 minutes of operation, including the mass flow rate and temperature of the salt inflow, tank salt inventory temperature, and inventory level for a representative molten salt tank design. These results form a database of tank operation behaviors that captures the effects of each specific parameter during charging, charging/discharging, and discharging processes.

14 SOLAR ENERGY↗
DOE OSTI2024

Development of Readily Available & Robust High Heat Flux Gardon Gauges

Concentrated solar power (CSP) technologies deliver concentrated solar energy as a heat source to industrial processes, power generation cycles, and chemical cycles. CSP systems require accurate and reliable high flux measurements, and next generation CSP systems will require flux measurement up to 1000 W/cm2. Existing flux measurement devices do not comprehensively meet the flux rating, cycle life, cost, and lead-time needs of stakeholders, necessitating the development of an improved flux sensor. In this study, Sandia National Laboratories (SNL) partnered with Hukseflux Thermal Sensors to develop a low-cost, short lead-time, and robust flux sensor rated to 250 W/cm2. Three prototype circular foil gauge designs were assessed for performance at the National Solar Thermal Test Facility (NSTTF) at SNL. Each gauge design measured flux up to 250 W/cm2 with <5% measurement error. Following baseline error quantification, gauges were exposed to flux above 500 W/cm2 to assess gauge failure mechanisms. Gauges physically survived >500 W/cm2 flux exposure, but measurement error was found to increase after foil coatings reached 400 °C. The results of this study suggest that coating optical properties change at excessive temperatures and that foil coating temperature, rather than heat flux level, dictates the acceptable gauge measurement range.

McLaughlin, Luke (ORCID:0000000303711310)↗
NASA NTRS1977

Analytical investigation of thermal barrier coatings on advanced power generation gas turbines

An analytical investigation of present and advanced gas turbine power generation cycles incorporating thermal barrier turbine component coatings was performed. Approximately 50 parametric points considering simple, recuperated, and combined cycles (including gasification) with gas turbine inlet temperatures from current levels through 1644K (2500 F) were evaluated. The results indicated that thermal barriers would be an attractive means to improve performance and reduce cost of electricity for these cycles. A recommended thermal barrier development program has been defined.

Amos, D. J.↗
NASA NTRS1995

Human Exploration and Settlement of the Moon Using LUNOX-Augmented NTR Propulsion

An innovative trimodal nuclear thermal rocket (NTR) concept is described which combines conventional liquid hydrogen (LH2)-cooled NTR, Brayton cycle power generation and supersonic combustion ramjet (scramjet) technologies. Known as the liquid oxygen (LOX) augmented NTR (LANTR), this concept utilizes the large divergent section of the NTR nozzle as an 'afterburner' into which LOX is injected and supersonically combusted with nuclear preheated hydrogen emerging from the LANTR's choked sonic throat--'scramjet propulsion in reverse.' By varying the oxygen-to-hydrogen mixture ratio (MR), the LANTR can operate over a wide range of thrust and specific impulse (Isp) values while the reactor core power level remains relatively constant. As the MR varies from zero to seven, the thrust-to-weight ratio for a 15 thousand pound force (klbf) NTR increases by approximately 440%--from 3 to 13--while the Isp decreases by only approximately 45%--from 940 to 515 seconds. This thrust augmentation feature of the LANTR means that 'big engine' performance can be obtained using smaller more affordable, easier to test NTR engines. 'Reoxidizing' the bipropellant LANTR system in low lunar orbit (LLO) with high density 'lunar-derived' LOX (LUNOX) enables a reusable, reduced size and mass lunar transfer vehicle (LTV) which can be deployed and resupplied using two 66 t-class Shuttle-derived launch vehicles. The reusable LANTR can also transport 200 to 300% more payload on each piloted round trip mission than an expendable 'all LH2' NTR system. As initial outposts grow to eventual lunar settlements and LUNOX production capacity increases, the LANTR concept can also enable a rapid 'commuter' shuttle capable of 36 to 24 hour 'one way' trips to the Moon and back with reasonable size vehicles and initial mass in low Earth orbit (IMLEO) requirements.

Borowski, Stanley K.↗
DOE OSTI2023

Life Cycle Analysis of Thermoelectric Power Generation in the United States

In this article, the basics of performing a life cycle analysis of thermoelectric power generation are discussed, with three examples of life cycle greenhouse gas (GHG) balances for thermoelectric power generation forms: coal, natural gas, and nuclear. The final section compares multiple electricity generation methods in the United States. Results are presented on the basis of 1 megawatt-hour (MWh) of electricity delivered to the end user. Environmental life cycle results for greenhouse gas (GHG) emissions are presented as carbon dioxide equivalents, based on 100-year global warming potentials (GWPs) established by the 6th Assessment Report from the Intergovernmental Panel on Climate Change in 2021, commonly referred to as AR6 GWP values (IPCC, 2021). Additional details on other environmental life cycle impacts from non-GHG emissions to air, emissions to water, solid waste generation, and land use are available on the Department of Energy, National Energy Technology Laboratory’s Life Cycle Analysis website: www.netl.doe.gov/LCA.

Cutshaw, Ashley↗
NASA NTRS1991

Solar powered Stirling cycle electrical generator

Under NASA's Civil Space Technology Initiative (CSTI), the NASA Lewis Research Center is developing the technology needed for free-piston Stirling engines as a candidate power source for space systems in the late 1990's and into the next century. Space power requirements include high efficiency, very long life, high reliability, and low vibration. Furthermore, system weight and operating temperature are important. The free-piston Stirling engine has the potential for a highly reliable engine with long life because it has only a few moving parts, non-contacting gas bearings, and can be hermetically sealed. These attributes of the free-piston Stirling engine also make it a viable candidate for terrestrial applications. In cooperation with the Department of Energy, system designs are currently being completed that feature the free-piston Stirling engine for terrestrial applications. Industry teams were assembled and are currently completing designs for two Advanced Stirling Conversion Systems utilizing technology being developed under the NASA CSTI Program. These systems, when coupled with a parabolic mirror to collect the solar energy, are capable of producing about 25 kW of electricity to a utility grid. Industry has identified a niche market for dish Stirling systems for worldwide remote power application. They believe that these niche markets may play a major role in the introduction of Stirling products into the commercial market.

Shaltens, Richard K.↗
DOE OSTI2022

Data-driven modeling of power generation for a coal power plant under cycling

Increased penetration of renewables for power generation has negatively impacted the dynamics of conventional fossil fuel-based power plants. The power plants operating on the base load are forced to cycle, to adjust to the fluctuating power demands. This results in an inefficient operation of the coal power plants, which leads up to higher operating losses. To overcome such operational challenge associated with cycling and to develop an optimal process control, this work analyzes a set of models for predicting power generation. Moreover, the power generation is intrinsically affected by the state of the power plant components, and therefore our model development also incorporates additional power plant process variables while forecasting the power generation. We present and compare multiple state-of-the-art forecasting data-driven methods for power generation to determine the most adequate and accurate model. We also develop an interpretable attention-based transformer model to explain the importance of process variables during training and forecasting. The trained deep neural network (DNN) LSTM model has good accuracy in predicting gross power generation under various prediction horizons with/without cycling events and outperforms the other models for long-term forecasting. The DNN memory-based models show significant superiority over other state-of-the-art machine learning models for short, medium and long range predictions. The transformer-based model with attention enhances the selection of historical data for multi-horizon forecasting, and also allows to interpret the significance of internal power plant components on the power generation. This newly gained insights can be used by operation engineers to anticipate and monitor the health of power plant equipment during high cycling periods.

01 COAL, LIGNITE, AND PEAT↗
NASA NTRS2005

Closed Cycle Magnetohydrodynamic Nuclear Space Power Generation Using Helium/Xenon Working Plasma

A multimegawatt-class nuclear fission powered closed cycle magnetohydrodynamic space power plant using a helium/xenon working gas has been studied, to include a comprehensive system analysis. Total plant efficiency was expected to be 55.2 percent including pre-ionization power. The effects of compressor stage number, regenerator efficiency, and radiation cooler temperature on plant efficiency were investigated. The specific mass of the power generation plant was also examined. System specific mass was estimated to be 3 kg/kWe for a net electrical output power of 1 MWe, 2-3 kg/kWe at 2 MWe, and approx.2 kg/KWe at >3 MWe. Three phases of research and development plan were proposed: (1) Phase I-proof of principle, (2) Phase II-demonstration of power generation, and (3) Phase III-prototypical closed loop test.

Litchford, R. J.↗
DOE OSTI2020

Generation of high-power few-cycle femtosecond IR pulses by double-chirp parametric amplification

We present an energy scalable configuration for the generation of high-power few-cycle femtosecond IR pulses based on the sequential parametric amplification of chirped radiation pulses at the idler (0.86 μm) and signal (1.39 μm) wavelengths from the multi-terawatt femtosecond laser system made at the Institute of Laser Physics, Siberian Branch of the Russian Academy of Sciences (ILP SB RAS). The configuration under consideration involves the sequential production of radiation pulses with centre wavelengths of 2.24, 3.56, and 7.25 μm. The conditions are determined for the generation of few-cycle pulses with a terawatt peak power in the 3.56 μm (15.8 fs, 1.5 cycles) and 7.25 μm (17.2 fs, shorter than one cycle) domains. The phase transfer between signal and idler waves in the double-chirp parametric amplification is investigated for the first time. (paper)

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
NASA NTRS2009

Microfabricated rankine cycle steam turbine for power generation and methods of making the same

In accordance with the present invention, an integrated micro steam turbine power plant on-a-chip has been provided. The integrated micro steam turbine power plant on-a-chip of the present invention comprises a miniature electric power generation system fabricated using silicon microfabrication technology and lithographic patterning. The present invention converts heat to electricity by implementing a thermodynamic power cycle on a chip. The steam turbine power plant on-a-chip generally comprises a turbine, a pump, an electric generator, an evaporator, and a condenser. The turbine is formed by a rotatable, disk-shaped rotor having a plurality of rotor blades disposed thereon and a plurality of stator blades. The plurality of stator blades are interdigitated with the plurality of rotor blades to form the turbine. The generator is driven by the turbine and converts mechanical energy into electrical energy.

Frechette, Luc↗
NASA NTRS1977

Conceptual design of closed Brayton cycle for coal-fired power generation

The objectives to be realized in developing a closed cycle gas turbine are (1) to exploit high temperature gas turbine technology while maintaining a working fluid which is free from combustion gas contamination, (2) to achieve compact turbo-equipment designs through pressurization of the working fluid, and (3) to obtain relatively simple cycle configurations. The technical/economic performance of a specific closed cycle gas turbine system was evaluated through the development of a conceptual plant and system design. This energy conversion system is designed for electric utility service and to utilize coal directly in an environmentally acceptable manner.

Shah, R. P.↗
DOE OSTI2024

Performance and Cost Potential of sCO2 Bottoming Cycle for Gas Turbines with Carbon Capture – Paper 32

This study investigates the performance and economic potential of sCO2 bottoming cycles for H-class gas turbine-based NGCC plants with a post-combustion capture system. A portion of the gas turbine exhaust heat is used for the generation of steam required for a solvent-based capture system while the rest of the waste heat is utilized in an sCO2 bottoming cycle for power generation. Overall, the performance and LCOE of investigated sCO2 bottoming cycles are similar to those of a state-of-the-art triple-pressure reheat steam Rankine cycle. As the gas turbine exhaust temperature increases (beyond 630oC), sCO2 bottoming cycles begin to show greater performance and economic benefits compared to a steam Rankine cycle with ~0.7 percentage point higher plant efficiency and 1.4% lower LCOE.

Pidaparti, Sandeep↗
DOE OSTI2020

NH 4 OH Looping with Membrane CO 2 Absorber and Distributed Stripper for Enhanced Algae Growth

The University of Kentucky Center for Applied Energy (UK CAER) has devised a unique, integrated CO2 capture and utilization technology. CO2 from coal-fired power generation flue gas is first captured at half the operating cost of a typical aqueous CO2 capture system (CCS), distributed in an aqueous stream and then fixed by algae in bioreactors where the algae production is increased by 50% over that with a typical intermittent nutrient feeding system. Lower CCS operating cost is achieved by eliminating the flue gas pretreatment step for cooling and SO2 removal, eliminating steam extraction from the power generation steam cycle for solvent regeneration, and eliminating CO2 compression. Higher algae production is achieved by continuous, just-in-time nutrient feed to the bioreactors directly from a distributed solvent regenerator, which maintains the bioreactor pH for optimum growth. The process starts with a uniquely configured membrane absorber, where the flue gas is indirectly contacted with an ammonium hydroxide (NH4OH) solvent. Dissolved NH3 is attractive for both CO2 capture and as an algae nutrient. For CO2 capture it is inexpensive, has a low regeneration energy, is thermally- and oxidatively-stable and has a viscosity near that of water, which makes is easy to transport. Numerous studies have shown that the scrubbing capacity of NH3 is approximately 0.9-1.2 kg of CO2/kg of NH3, with a CO2 removal efficiency of ~99% and half the solvent regeneration energy than that of 30 wt% MEA[1, 2, 3]. NH3 is attractive as an algae nutrient due to its low cost. The rich NH4OH solvent is pumped to a set of distributed regenerators which are co-located with the algae bioreactors. Solvent pumping, transport and distribution reduces the balance of plant (BOP) cost compared to a typical aqueous CCS related to the flue gas duct and boost fan required to transport the flue gas. The energy required for the distributed solvent regeneration is supplied by solar-thermal panels eliminating the need for steam extraction from the power generation steam cycle. After solvent regeneration, the product stream contains both the CO2 captured from the flue gas and volatized NH3 from the solvent. This product stream is fed directly to the bioreactors, eliminating the need for compression of the CO2 stream. The relative amounts of CO2 and NH3 in the product stream are adjusted and controlled by a controlling the regeneration conditions (pressure and temperature). The continuous feed of the right ratio of nutrients overcomes the typical inhibition of algae growth resulting from frequent pH swings in the bioreactor due to unbalanced (intermittent) feeding systems for CO2 and N. Also, because the regenerators will operate at pressure and be located in close proximity to the bioreactors, there is no worry about pressure drop when sparging the gas into the algae. Sparging produces small bubbles which is beneficial for mass transfer efficiency. One known challenge when using an NH4OH solvent is high NH3 emission. Hydrophobic membranes are used for CO2 capture using an aqueous NH3 solution[4, 5] without the direct contact between flue gas and aqueous solution. Additionally, UK CAER CO2 capture and utilization process manages NH3 slip in three extra measures. First, NH3 slip is minimized by working with minimal species partial pressure, which is proportional to the concentration in the liquid. Hence, lowering the capture solvent concentration will lower the NH3 partial pressure. Second, UK CAER’s previous work has demonstrated that the addition of Zn2+ into NH3 solutions to chelate the NH3 can reduce NH3 volatility. Third, the configuration of the membrane CO2 absorber utilizes condensed water from the flue gas to continually wash the gas-side of the membrane to reduce fouling and recapture NH3 slip. Additional details about the UK CAER unique, integrated CO2 capture and utilization technology will be presented along with technology development plans. Diao, N., Q. Li, and Z. Fang. 2004. Heat transfer in ground heat exchangers with groundwater advection. International Journal of Thermal Sciences. 43: 1203-1211, He, Q., M. Chen, L. Meng, K. Liu, and W. Pan. 2004. Study on Carbon Dioxide Removal from Flue Gas by Absorption of Aqueous Ammonia. Western Kentucky University. Yeh, A.C., and H. Bai. 1999. Comparison of ammonia and monoethanolamine solvents to reduce CO2 greenhouse gas emissions. The Science of the Total Environment. 228: 121-133, Villeneuve, K., D. Roizard, J.C. Remigy, M. Iacono, and S. Rode. 2018. CO2 capture by aqueous ammonia with hollow fiber membrane contactors: Gas phase reactions and performance stability. Separation and Purification Technology, 199: 189-197, Toro Molina, C., and C. Bouallou. 2016. Carbon dioxide absorption by ammonia intensified with membrane contactors. Clean Techn Environ Policy 18, 2133–2146 (2016)

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2025

Rapid Bayesian High Entropy Alloy Designs Fabricated via Wire Arc Additive Manufacturing

Purpose: This project seeks to demonstrate a new high-throughput (rapid) alloy design technique applied to creating new high entropy alloys (HEAs) for extreme environments. High entropy alloys shift the design paradigm from being focused on a single principal element (e.g. nickel-based alloys) to target alloys that include high atomic fractions (X >10%) of multiple elements. These HEA materials can exhibit sluggish diffusion and enhanced corrosion resistance, ideal for potential applications in advanced ultra supercritical (A-USC) steam cycles for power generation. Scope: The addition of multiple elements in high atomic fractions creates an enormous design space that cannot easily be investigated by traditional material design strategies such as designed of experiments (DOE). This project utilizes a Bayesian machine learning algorithm that has been modified to work with calculation of phase diagrams (CALPHAD) software. This Bayesian algorithm reduces manual inputs and increase the likelihood of achieving an optimal solution. Compositional inputs to this algorithm will be assessed using existing material property models for high temperature strength and corrosion resistance. The target for alloy performance will be a 15% (~100 ⁰C) increase in allowable service temperature beyond heat-resistant stainless steels while maintaining or improving alloy cost and corrosion resistance. Haynes 230 was selected as a baseline, which is 57 wt% Ni with 22 wt% Cr 14 wt% W, and 2 wt% Mo as solid solution strengtheners. In addition to rapid design via Bayesian machine learning, the alloys were rapidly fabricated using a multi-wire arc additive manufacturing (mWAAM) technique which allows for precise control of alloy composition and assessing of alloy design “windows” to study composition effects. Build speeds for wire-arc additive processes are among the highest for additive technologies enabling rapid and reliable sample fabrication when compared to conventional methods such as arc button melting. The mWAAM samples will be rapidly characterized via instrumented indentation for room temperature modulus and strength and for elevated temperature strength via hot hardness tests. After being screened with hardness testing, potential alloys will be further evaluated with conventional microscopy techniques including scanning electron microscopy (SEM) and transmission electron microscopy (TEM) to assess agreement with modeling results. The most promising compositions will also be evaluated by printing full sized tensile specimens for mechanical behavior tests at elevated temperatures. Results: Bayesian machine learning of a single performance function was initially used to optimize five performance metrics: 1) single phase stability, 2) yield strength, 3) creep resistance (low diffusion coefficient), 4) freezing range (weldability), and 5) material cost. The single performance function was suboptimal as assumptions had to be made about the results while formulating the optimization. A goal-oriented Bayesian optimization strategy (Hanaoka, 2021) was implemented with CALPHAD for use with the five metrics above. This multi-objective Bayesian optimization (MOBO) enabled the design of NiCrCoFe alloys with V and W additions. A base composition of NiCoCr was selected as Ni provides a stable FCC matrix, Cr aids corrosion/oxidation resistance, and Co is a solid-solutions strengthener that also improves creep by increasing the activation energy. Fe helps reduce diffusion coefficients and cost. Finally, V and W were selected for their reasonable solubility and high atomic misfit to aid in solid solution strengthening. Cracking of the mWAAM specimens was an early issue, and the Easton solidification cracking model (Easton et al., 2014a) was selected for addition to the MOBO function. High performing alloys fabricated by mWAAM included Ni 28 Cr 25 Co 26 Fe 15 V 8 and Ni 62 Cr 18 Co 1 Fe 3 W 15 . It was observed that even after adapting the mWAAM process for W, the W did not fully dissolve. To fully evaluate the Ni 62 Cr 18 Co 1 Fe 3 W 15 composition, a cored wire (80-20 NiCr sheath/powder core) was manufactured and printed via WAAM, and HIP’ing was utilized to homogenize and densify the printed alloy. The V and W alloys produced met metrics 1 (solid solution), 4 (solidification cracking), and 5 (cost). However, an unmodeled mechanism of thermal stress cracking was identified in the WAAM produced materials, perhaps exacerbated by the lack of grain boundary strengthening elements (B, C). Conclusions & Recommendations: A high-throughput (rapid) alloy design technique was applied to designing and manufacturing new high entropy alloys (HEAs) for extreme environments utilizing MOBO and mWAAM. The developed process was rapid and effective in addressing the mechanisms included in the model. The lack of grain boundary strengthening element additions (e.g., B, C) was a simplification that likely produced thermal stress cracking that turned into a large part of the investigation. Additions on the order of 0.005 wt% B and 0.05 wt% C likely would have minimized thermal stress grain boundary cracking. Overall, the high throughput design strategy is promising for rapid design of metrics-driven alloys for advanced ultra supercritical (A-USC) steam cycles for power generation. The MOBO and mWAAM process could be commercialized to accelerate metrics-driven alloy design. In addition, the cored-wire process utilized for scale-up is a promising high-volume process for WAAM alloy development and scale-up.

36 MATERIALS SCIENCE↗