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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 685 records · Page 38

Distinctive Oxide Films Develop on the Surface of FeCrAl as the Environment Changes for Nuclear Fuel Cladding

The corrosion-resistant properties of IronChromium–Aluminum (FeCrAl) alloys have been known for nearly a century. Since the 1950s, they have been explored for application in the generation of nuclear power. In the last decade, the focus has been on the use of FeCrAl as cladding for uranium dioxide fuel in light water reactors (LWRs). The corrosion resistance of this alloy depends on the oxide that it can develop on the surface. In LWRs in the vicinity of 300 °C, the external surface oxide of the FeCrAl cladding could be rich in Fe under oxidizing conditions but rich in Cr under reducing conditions. If there is an accident and the cladding is exposed to superheated steam, the cladding will protect itself by developing an alpha aluminum film on the surface.

Qu, Haozheng↗

Elucidating the Transition of 3D Morphological Evolution of Binary Alloys in Molten Salts with Metal Ion Additives

Molten salts serve as effective high-temperature heat transfer fluids and thermal storage media used in a wide range of energy generation and storage facilities, including concentrated solar power plants, molten salt reactors and high-temperature batteries. However, at the salt–metal interfaces, a complex interplay of charge-transfer reactions involving various metal ions, generated either as fission products or through corrosion of structural materials, takes place. Simultaneously, there is a mass transport of ions or atoms within the molten salt and the parent alloys. The precise physical and chemical mechanisms leading to the diverse morphological changes in these materials remain unclear. Here, to address this knowledge gap, this work employed a combination of synchrotron X-ray nanotomography and electron microscopy to study the morphological and chemical evolution of Ni-20Cr in molten KCl-MgCl 2 , while considering the influence of metal ions (Ni 2+ , Ce 3+ , and Eu 3+ ) and variations in salt composition. Our research suggests that the interplay between interfacial diffusivity and reactivity determines the morphological evolution. The summary of the associated mass transport and reaction processes presented in this work is a step forward toward achieving a fundamental comprehension of the interactions between molten salts and alloys. Overall, the findings offer valuable insights for predicting the diverse chemical and structural alterations experienced by alloys in molten salt environments, thus aiding in the development of protective strategies for future applications involving molten salts.

36 - MATERIALS SCIENCE↗

Oxidation-Resistant Surfaces For Solar Reflectors

Thin films on silver provide highly-reflective, corrosion-resistant mirrors. Study evaluated variety of oxidation-resistant reflective materials for use in solar dynamic power system, one that generates electricity by focusing Sunlight onto reciever of heat engine. Thin films of platinum and rhodium deposited by ion-beam sputtering on various substrate materials. Solar reflectances measured as function of time of exposure to radio-frequency-generated air plasma. Several protective coating materials deposited on silver-coated substrates and exposed to plasma. Analyzed before and after exposure by electon spectroscopy for chemical analysis and by Auger spectroscopy.

Gulino, Daniel A.↗

The Effect of Continuous Weathering on Light Metal Alloys Used in Aircraft

An investigation of the corrosion of light metal alloys used in aircraft was begun at the National Bureau of Standards in 1925 and has for its purpose causes of corrosion in aluminum-rich and magnesium-rich alloys together with the development of methods for its prevention. The results, obtained in an extensive series of laboratory and weather-exposure tests, reveal the relative durability of a number of commercially available materials and the extent to which the application of various surface coatings of oxide alone and with paint coatings afforded additional protection. The paper may be considered as a supplement to NACA report 490.

Mutchler, Willard↗

High Temperature Photovoltaics Silicone Adhesives for Venus Surface

The harsh environment at the surface of Venus, with a low solar intensity, red-rich solar spectrum, high temperatures, and a corrosive acid environment, makes it a challenging location to use photovoltaics. For the design of photovoltaic power generation for future missions to Venus, solar arrays that can function at high temperatures under low light intensity must be developed, and a significant difficulty in this is achieving a long lifetime without degradation under Venus conditions. One issue that must be addressed is the encapsulation to protect the solar cells from the environment, and most particularly the transparent adhesive affixing the coverglass to the cells. In this paper the factors affecting the reliability and degradation of transparent silicone adhesives under Venus conditions are discussed.

Katampe, Ibrahim↗

Oxidation of Alumina-Forming MAX Phases in Turbine Environments

Protective coatings for high temperature turbine components are based on YSZ thermal barriers and oxidation resistant, alumina-forming NiAl or NiCoCrAlY bond coats. Ti2AlC and Cr2AlC MAX phases are thus of special interest because of good oxidation resistance and CTE that can match Al2O3 and YSZ. Their alumina scales grow according to cubic kinetics due to grain growth in the scale, with initial heating dominated by fast TiO2 growth. Protective cubic kinetics are also found in high pressure burner rig tests of MAXthal 211 Ti2AlC, but with reduced rates due to volatile TiO(OH)2 formation in water vapor. YSZ-coatings on bulk Ti2AlC exhibit remarkable durability up to 1300C in furnace tests and at least a 25x life advantage compared to superalloys. At another extreme, Cr2AlC is resistant to low temperature Na2SO4 hot corrosion and exhibits thermal cycling stability bonded to a superalloy disk material. Accordingly, sputtered Cr2AlC coatings on disk specimens prevented hot corrosion detriments on LCF. Breakaway oxidation (Ti2AlC), scale spallation (Cr2AlC), interdiffusion, and processing as coatings still present serious challenges. However the basic properties of MAX phases provide some unusual opportunities for use in high temperature turbines.

ceramics↗

Evaluation of Desiccation Behavior in Basalt Microfiber–Reinforced Bentonite Clay for Geological Repositories of Nuclear Spent Fuel Using Digital Image Correlation

ABSTRACT Secure storage of nuclear spent fuel (NSF) is of great concern for protecting public health and safety. The preferred long-term solution is underground containment in geological repositories, where one or more engineered barrier materials (EBM) encapsulate the NSF and separate it from the natural rock. Bentonite clay is commonly used as an EBM due to its many advantageous properties including low hydraulic conductivity, which ensures limitation of water infiltration to the system and the subsequent risk of corrosion in NSF canisters. However, bentonite clay subjected to heating from nuclear decay may form desiccation cracking. This study conducted disk-shaped free shrinkage tests and ring-shaped restrained shrinkage tests of bentonite clay samples reinforced with basalt microfibers. Digital image correlation was used as a noncontact full-field displacement measurement to track the time-evolving shrinkage and desiccation cracking phenomena and make quantified comparisons between plain bentonite and bentonite with varying contents of basalt microfibers (i.e., 0.0, 0.5, 1.0, and 1.5 % wt.). Results indicate that plain bentonite and basalt microfiber-reinforced samples showed similar free shrinkage behavior, while desiccation cracking behavior was significantly altered by adding basalt microfibers. Microfiber reinforcement effectively reduced major cracks through a “crack-bridging” effect while causing minor cracks to initiate earlier and at higher moisture contents than plain bentonite. Results infer that reinforcing plain bentonite with inorganic microfibers can potentially control desiccation cracking, leading to safer and improved nuclear waste management.

Materials Science↗

Sandblasting nozzle

A nozzle for use with abrasive and/or corrosive materials is formed of sintered ceramic compositions having high temperature oxidation resistance, high hardness and high abrasion and corrosion resistance. The ceramic may be a binary solid solution of a ceramic oxide and silicon nitride, and preferably a ternary solid solution of a ceramic oxide, silicon nitride and aluminum nitride. The ceramic oxide is selected from a group consisting of Al2O3, Y2O3 and Cr2O3, or mixtures of those compounds. Titanium carbide particles are dispersed in the ceramic mixture before sintering. The nozzles are encased for protection from external forces while in use by a metal or plastic casing.

Perkins, G. S.↗

Wrapped Wire Detects Rupture Of Pressure Vessel

Simple, inexpensive technique helps protect against damage caused by continuing operation of equipment after rupture or burnout of pressure vessel. Wire wrapped over area on outside of vessel where breakthrough most likely. If wall breaks or burns, so does wire. Current passing through wire ceases, triggering cutoff mechanism stopping flow in vessel to prevent further damage. Applied in other situations in which pipes or vessels fail due to overpressure, overheating, or corrosion.

Hunt, James B.↗

Multilayer Architecture Barriers for High Temperature Nuclear Applications

Innovative thin film multilayer metal/ceramic barrier coatings have been developed by Argonne National Laboratory to protect fuel cladding against different phenomena that can be encountered under the harsh operating conditions of advanced nuclear reactors. One phenomenon is Fuel-Cladding Chemical Interaction (FCCI), which can represent a challenge to the performance of steel-clad metallic fuels in sodium-cooled fast reactors (SFRs), especially when operating to high burnups at elevated cladding temperatures, and long fuel residence time. Another phenomenon is the corrosion of zirconium-based cladding under prototypic boiling water reactor (BWR) conditions and associated cladding during off normal conditions, including loss of coolant accidents (LOCA). This work provides details of the development and testing of a thin film (few microns) multilayer metal/ceramic (CrY/Y 2 O 3 ) coatings on steel cladding and its performance against FCCI. The coating architecture evolved through systematic mechanical testing, radiation tolerance assessments, and high-temperature diffusion studies from a preliminary multilayer concept to an optimized high-performance design. The optimized structure leverages stoichiometric Y 2 O 3 for its exceptional radiation stability, chemical inertness, and ultra-low fission product diffusivity (e.g., Ce diffusivity ~10 -20 m 2 /s in irradiated Y 2 O 3 at 650 °C). This is paired with ductile chromium-rich interlayers (Cr 95 Y 5 ), which significantly enhance fracture toughness and mechanical resilience. Design refinements, including increased ceramic layer thickness and optimized Cr–Y interlayer composition, eliminated fracture propagation and preserved coating integrity under extreme mechanical stress (>10× typical reactor conditions) and prolonged radiation exposure (~300 dpa). Those conditions are well beyond expected conditions during normal operations in SFR, and cover some of the transient conditions as well. In addition, the coating deposition was demonstrated to be applied uniformly to the inner surface of steel tubes representing prototypic SFR cladding. Another phenomenon under consideration in this work is the corrosion of zirconium-based cladding under prototypic boiling water reactor (BWR) conditions and associated off normal conditions including loss of coolant accident (LOCA). Another multilayer thin film coating is considered for mitigation of this phenomenon, where a coating of yttrium aluminum and yttrium aluminum ceramic/metal thin film coating. Preliminary results on the coating performance during high temperature thermal cycling (up to 1000 C) have shown promising performance of the coating. On-going optimization of the coating will continue in FY26.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Chemical durability assessment of enhanced low-activity waste glasses through EPA method 1313

In this work, we report the progress of the Glass Leaching Assessment for Durability (GLAD) program on the implementation of the United States Environmental Protection Agency (EPA) Leaching Environmental Assessment Framework pH-dependent leach test (EPA Method 1313) to low-activity nuclear waste (LAW) glasses. The GLAD program seeks to develop new strategies to understand the chemical durability of nuclear waste glasses for the disposal in near-surface conditions. A series of 16 high-waste loading LAW glasses, currently under development, were selected using machine learning methods to study the corrosion behavior using EPA Method 1313. Reacted glass powders were examined using scanning electron microscopy and the eluate compositions were examined using inductively coupled plasma-optical emission spectroscopy. Compositional modeling was used to fit the measured elemental releases from EPA Method 1313. The compositional models demonstrated that elements such as Si reduce elemental release while B can increase elemental release (consistent with elemental modeling of the Product Consistency Test and Vapor Hydration Test) while other elements, such as Fe, exhibit pH-dependent behavior. The amount of acid added during the EPA testing was found to significantly impact the observed result, which was only apparent after preforming the present matrix study. The overall titration curves were able to be compositionally modeled for future process optimization.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Scattering defects in silver mirror coatings

Scatter centers common to protected silver have been investigated on a variety of space flight quality mirrors. The defects have been characterized as to number density, size, location within the film layer structure, and dependence on illumination angle. In addition the total integrated scatter values as a function of wavelength, humidity test soak time, and temperature have been determined for some mirrors. These submicrometer sized defects are believed to be the precursors of silver corrosion spots. A mechanism for their generation is proposed, and measures to reduce their occurrence are suggested.

Pellicori, S. F.↗

CRADA Final Report: CRADA Number NFE-22-09311 with Agriwater Tech

Livestock wastewater management is a critical concern in the United States, with an annual production of approximately 1.37 billion tons of waste, surpassing human waste by three to twenty times. The mismanagement of manure wastewater poses significant threats to freshwater sources, ecosystems, and public health. Through this project, we proposed an innovative solution using electrocoagulation (EC) treatment. The EC technique is an electrochemical process involving the intentional corrosion of aluminum and iron electrodes to introduce trivalent ions into the solution, facilitating the co-precipitation and coagulation of contaminants and making the removal of water from sludge easier. The project's primary objective is to use EC to convert liquid animal manure into clean water for farm irrigation, drinking, and maintenance. This solution is vital for various farms including those facing drought, pursuing zero-discharge, and seeking Environmental Protection Agency (EPA) permits for livestock farm manure discharge into rivers. Preliminary research shows EC's potential to significantly reduce turbidity and phosphate levels in livestock wastewater, forming the basis for scalable onsite treatment. The goal of this proposed project is to develop an innovative farm-wastewater-treatment process to achieve clean water, fertilizer, and reduced greenhouse gases through electrification of current processes such as coagulation, dewatering, inactivation of viruses and bacteria, and filtration for recycling surface water from farm lagoons.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

CRADA Final Report: CRADA Number NFE-22-09311 with Agriwater Tech

Livestock wastewater management is a critical concern in the United States, with an annual production of approximately 1.37 billion tons of waste, surpassing human waste by three to twenty times. The mismanagement of manure wastewater poses significant threats to freshwater sources, ecosystems, and public health. Through this project, we proposed an innovative solution using electrocoagulation (EC) treatment. The EC technique is an electrochemical process involving the intentional corrosion of aluminum and iron electrodes to introduce trivalent ions into the solution, facilitating the co-precipitation and coagulation of contaminants and making the removal of water from sludge easier. The project's primary objective is to use EC to convert liquid animal manure into clean water for farm irrigation, drinking, and maintenance. This solution is vital for various farms including those facing drought, pursuing zero-discharge, and seeking Environmental Protection Agency (EPA) permits for livestock farm manure discharge into rivers. Preliminary research shows EC's potential to significantly reduce turbidity and phosphate levels in livestock wastewater, forming the basis for scalable onsite treatment. The goal of this proposed project is to develop an innovative farm-wastewater-treatment process to achieve clean water, fertilizer, and reduced greenhouse gases through electrification of current processes such as coagulation, dewatering, inactivation of viruses and bacteria, and filtration for recycling surface water from farm lagoons.

54 ENVIRONMENTAL SCIENCES↗

Novel Environmental Barrier Coatings for the Protection of SiC Components

Greater gas turbine engine efficiency is a major goal in aeronautics research often pursued through increased engine operating temperatures. However, it is necessary to replace the current hot-stage alloy components with more thermally robust parts, such as Silicon-based ceramics and composites. Unfortunately, these materials are still susceptible to the effects of oxidation, water vapor, and (Calcium-Magnesium-Alumino-Silicate) CMAS interaction, among other issues at high temperature. To mitigate these effects, environmental barrier coating (EBC) materials are employed to help control the rate of degradation to the underlying composite, but must also survive the corrosive environment. The current study explores new design space in Mg-based EBC materials with respect to microstructure, high temperature phase stability, volatilization in water vapor, as well as structure-property relationships at high temperature.

Kowalski, Benjamin A.↗

Extreme Environment Technologies for Space and Terrestrial Applications

Over the next decades, NASA's planned solar system exploration missions are targeting planets, moons and small bodies, where spacecraft would be expected to encounter diverse extreme environmental (EE) conditions throughout their mission phases. These EE conditions are often coupled. For instance, near the surface of Venus and in the deep atmospheres of giant planets, probes would experience high temperatures and pressures. In the Jovian system low temperatures are coupled with high radiation. Other environments include thermal cycling, and corrosion. Mission operations could also introduce extreme conditions, due to atmospheric entry heat flux and deceleration. Some of these EE conditions are not unique to space missions; they can be encountered by terrestrial assets from the fields of defense,oil and gas, aerospace, and automotive industries. In this paper we outline the findings of NASA's Extreme Environments Study Team, including discussions on state of the art and emerging capabilities related to environmental protection, tolerance and operations in EEs. We will also highlight cross cutting EE mitigation technologies, for example, between high g-load tolerant impactors for Europa and instrumented projectiles on Earth; high temperature electronics sensors on Jupiter deep probes and sensors inside jet engines; and pressure vessel technologies for Venus probes and sea bottom monitors. We will argue that synergistic development programs between these fields could be highly beneficial and cost effective for the various agencies and industries. Some of these environments, however, are specific to space and thus the related technology developments should be spear headed by NASA with collaboration from industry and academia.

extreme environments↗

Molten Silicate Reactivity with Environmental Barrier Coating Materials for Gas Turbine Engine Applications

Rare earth (RE) disilicates are utilized in environmental barrier coatings (EBCs) to protect SiC-based ceramic matrix composites (CMCs) from destructive reactions with water vapor and other combustion species. These coating materials, however, degrade when exposed to molten silicate deposits primarily composed of calcium-magnesium aluminosilicates (CMAS). Coating materials are exposed to CMAS by engine ingestion of dust particulates from terrestrial sources during operation. Due to continual increases in engine operating temperature, it is important to understand the high temperature thermochemical mechanisms that drive corrosion of these materials. This work focuses on characterizing reaction products between disilicates and CMAS and optimizing coating chemistries to mitigate damage.

Stokes, Jamesa L.↗

Revisiting Wagner’s Criteria to Predict Establishment and Retention of Alumina Scales on Ternary NiCrAl Alloys

Despite the advent of numerical modeling approaches and high-performance computing infrastructure, the design and development of corrosion-resistant high temperature alloys (> 500 °C) continue to be largely empirical and typically involve extensive experimentation. This is mainly due to the lack of a single unified physics-based model that can address the impact of multiple competing factors such as time, environment, alloy composition, microstructure, and geometry. The classical Wagner’s criteria have been foundational to estimate the minimum concentrations required of an oxide-forming element to establish and sustain a protective oxide scale. However, the formulation is primarily limited to lower-order alloy systems (binary alloys) and ignores the time dependence of subsurface compositional changes in the alloy. The lack of key data on the temperature and composition dependence of the solubility and transport of oxidants in multicomponent-multiphase alloys further exacerbates the problem. In the present work, a few of these limitations were addressed using a flux-based approach (FLAP) which tracks the spatiotemporal evolution of the fundamental flux balance between oxygen and the oxide-forming elements to enable the prediction of the formation of an external alumina scale in ternary NiCrAl alloys. In conclusion, the modeling results were validated with the literature findings and additional experimental work conducted in the present work.

36 MATERIALS SCIENCE↗