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At least 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Demonstration of an All-Refractory Corrosion-Resistant Molten Salt Pumping and Storage Infrastructure Up to 950 degrees C

Concentrating solar power (CSP) with thermal energy storage (TES) has an estimated cost similar to solar photovoltaics (PV) with lithium-ion batteries (LIB), but CSP + TES has the potential for significantly reduced cost by operating above 700 degrees C. However, this requires a TES medium and containment infrastructure which are chemically compatible and do not degrade above 700 degrees C. MgCl2-KCl-NaCl (MKN) salt is a promising medium, but when MKN salt has small amounts of water and oxygen dissolved in it, it excessively corrodes conventional commercial alloys. Here, we consider refractory materials including graphite, carbon-carbon composite (C/C), and molybdenum because they maintain high mechanical strength at elevated temperatures and are expected to resist corrosion by MKN salt. While selection of refractory materials is often constrained by the need to remain chemically stable in air, this work uses an enclosure filled with inert gas to allow the use of materials like graphite and molybdenum. Notably, graphite components can seal against liquids unlike many brittle refractory materials. We demonstrate a centrifugal pump and mechanical seals made of refractory materials in a laboratory-scale circulation loop, which successfully operated continuously for more than 49 h at temperatures ranging from 750 degrees C to 950 degrees C with no mechanical failures or chemical degradation of the refractory materials. To the best of our knowledge, this is the highest temperature molten salt circulation loop that has been successfully developed, and this refractory infrastructure allows for operation at even much higher temperatures (<1600 degrees C) if a storage medium with a lower vapor pressure is used. The principles of this architecture are relevant to other applications with high temperature flowing metals and salts including Generation IV nuclear fission reactors for power production and molten salt electrolysis reactors for metallurgical processing.

14 SOLAR ENERGY↗
DOE OSTI2015

ICE CHEMISTRY ON OUTER SOLAR SYSTEM BODIES: ELECTRON RADIOLYSIS OF N{sub 2}-, CH{sub 4}-, AND CO-CONTAINING ICES

Radiation processing of the surface ices of outer Solar System bodies may be an important process for the production of complex chemical species. The refractory materials resulting from radiation processing of known ices are thought to impart to them a red or brown color, as perceived in the visible spectral region. In this work, we analyzed the refractory materials produced from the 1.2-keV electron bombardment of low-temperature N{sub 2}-, CH{sub 4}-, and CO-containing ices (100:1:1), which simulates the radiation from the secondary electrons produced by cosmic ray bombardment of the surface ices of Pluto. Despite starting with extremely simple ices dominated by N{sub 2}, electron irradiation processing results in the production of refractory material with complex oxygen- and nitrogen-bearing organic molecules. These refractory materials were studied at room temperature using multiple analytical techniques including Fourier-transform infrared spectroscopy, X-ray absorption near-edge structure (XANES) spectroscopy, and gas chromatography coupled with mass spectrometry (GC-MS). Infrared spectra of the refractory material suggest the presence of alcohols, carboxylic acids, ketones, aldehydes, amines, and nitriles. XANES spectra of the material indicate the presence of carboxyl groups, amides, urea, and nitriles, and are thus consistent with the IR data. Atomic abundance ratios for the bulk composition of these residues from XANES analysis show that the organic residues are extremely N-rich, having ratios of N/C ∼ 0.9 and O/C ∼ 0.2. Finally, GC-MS data reveal that the residues contain urea as well as numerous carboxylic acids, some of which are of interest for prebiotic and biological chemistries.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

EXPERIMENTAL INVESTIGATION OF IMPACT AND ABRASION EROSIONS AT LOW VELOCITIES AND COMPARISON TO CFD SIMULATIONS

Wear and erosion damage of materials due to interaction of the surface with solid particles is a major issue in various industries. This phenomenon is common in mining, and oil and gas production, causing damages worth millions of dollars annually. Erosion is becoming a critical issue in renewable technologies as well such as concentrated solar thermal power (CSP) systems. In some CSP systems, solid particles can be used to absorb solar energy and enhance the heat storage. However, these particles may cause significant amount of wear to system components while falling down the power tower at high temperatures. This damage can be costly, and therefore, investigating solid particle erosion in CSP systems is of utmost importance. In collaboration with Sandia National Laboratories, the erosion durability of particle-based Generation 3 (GEN3) CSP system are being investigated both experimentally and numerically. In order to develop models to predict the life time of such systems, erosion under low temperature and low particle impact velocity conditions are investigated. Impact erosion and abrasion erosion experiments are conducted for low velocity and low temperature conditions for various candidate particles and containment materials. The impact erosion testing is conducted for three different containment material including Stainless Steel 316, special refractory material, and Inconel 740H with CARBOBEAD HSP 40/70 ceramic particles and UNIWEST 430 silica quartz erodent particles. All this data will enable us to better model the erosion behavior of these materials and provides a data base to investigate erosion at high temperatures experienced in CSP systems. At low temperatures and low velocities the softer refractory material exhibited greater erosion by an order-of-magnitude when compared to the harder Inconel 740H and Stainless Steel 316 materials. The overall erosion ratio for all the candidate materials was of the order of 10 -7 kg/kg. We also investigated wear in containment materials from sliding of particles over the surfaces at very low angles, also referred to as abrasion. For the velocities expected in a typical 1MW CSP plant, visible surface wear was noted, but the overall mass loss per unit surface area was found to be dependent on the hardness of the containment material tested. In this manuscript, we also present Computational Fluid Dynamics (CFD) simulations and erosion prediction of low velocity impact erosion. These results are compared with the experimental data to evaluate the ability of available erosion models for predicting erosion under these conditions.

14 SOLAR ENERGY↗
NASA NTRS1993

Test model designs for advanced refractory ceramic materials

The next generation of space vehicles will be subjected to severe aerothermal loads and will require an improved thermal protection system (TPS) and other advanced vehicle components. In order to ensure the satisfactory performance system (TPS) and other advanced vehicle materials and components, testing is to be performed in environments similar to space flight. The design and fabrication of the test models should be fairly simple but still accomplish test objectives. In the Advanced Refractory Ceramic Materials test series, the models and model holders will need to withstand the required heat fluxes of 340 to 817 W/sq cm or surface temperatures in the range of 2700 K to 3000 K. The model holders should provide one dimensional (1-D) heat transfer to the samples and the appropriate flow field without compromising the primary test objectives. The optical properties such as the effective emissivity, catalytic efficiency coefficients, thermal properties, and mass loss measurements are also taken into consideration in the design process. Therefore, it is the intent of this paper to demonstrate the design schemes for different models and model holders that would accommodate these test requirements and ensure the safe operation in a typical arc jet facility.

Tran, Huy Kim↗
DOE OSTI2014

In Situ Diffraction from Levitated Solids Under Extreme Conditions—Structure and Thermal Expansion in the Eu 2 O 3 –ZrO 2 System

The accurate determination of structure and thermal expansion of refractory materials at temperatures above 1500°C is challenging. Here, for the first time, we demonstrate the ability to reliably refine the structure and thermal expansion coefficient of oxides at temperatures to 2200°C using in situ synchrotron diffraction coupled with aerodynamic levitation. Solid solutions in the Eu 2 O 3 –ZrO 2 binary system were investigated, including the high‐temperature order–disorder transformation in Eu 2 Zr 2 O 7 . The disordered fluorite phase is found to be stable above 1900°C, and a reversible phase transition to the pyrochlore phase is noticed during cooling. Site occupancies in Eu 2 Zr 2 O 7 show a gradual increase in disorder on both cation and anion sublattices with increasing temperature. The thermal expansion coefficients of all cubic solid solutions are relatively similar, falling in the range 8.6–12.0 × 10 −6 C −1 . These studies open new vistas for in situ exploration of complex structural changes in high‐temperature materials.

Maram, Pardha S.↗
NASA NTRS2001

Metal Matrix Composite LOX Turbopump Housing Via Novel Tool-Less Net-Shape Pressure Infiltration Casting Technology

Metal matrix composites (MMC) offer relatively higher specific strength, specific stiffness, lower coefficient of thermal expansion (CTE) and lower density as compared with conventional alloys. These unique properties make them very attractive for aerospace turbomachinery applications where there is ever increasing emphasis to reduce weight and cost, and to increase engine performance. Through a joint effort between NASA and Metal Matrix Cast Composites, Inc., a complex liquid oxygen (LOX) compatible turbopump housing is being redesigned and manufactured from hybrid (particulate and fibers) Aluminum MMC. To this end, a revolutionary tool-less pressure infiltration casting technology is being perfected. Ceramic preforms for the composite are 3-dimensionally printed using a stereolithography file, acquired from a CAD model. The preforms are then invested into a refractory material and pressure infiltrated with liquid metal. After casting, the refractory material is washed away leaving behind a near net-shape composite part. Benefits of this process include increased composite uniformity, no mold machining, short time from design to part, properties matching traditional methods, ability to make previously impossible to manufacture parts and no size limitations with a newly developed joining technology. The results of materials, manufacturing and design optimizations, preform joining, and sub-element tests will be presented.

Shah, Sandeep↗
NASA NTRS2001

Metal Matrix Composite LOX Turbopump Housing Via Novel Tool-Less Net-Shape Pressure Infiltration Casting Technology

Metal matrix composites (MMC) offer relatively higher specific strength, specific stiffness, lower coefficient of thermal expansion (CTE) and lower density as compared with conventional alloys. These unique properties make them very attractive for aerospace turbomachinery applications where there is ever increasing emphasis to reduce weight and cost, and to increase engine performance. Through a joint effort between NASA and Metal Matrix Cast Composites, Inc., a complex liquid oxygen (LOX) compatible turbopump housing is being redesigned and manufactured from hybrid (particulate and Fibers) Aluminum MMC. To this end, a revolutionary tool-less pressure infiltration casting technology is being perfected. Ceramic preforms for the composite are 3-dimensionally printed using a stereolithography file, acquired from a CAD model. The preforms are then invested into a refractory material and pressure infiltrated with liquid metal. After casting, the refractory material is washed away leaving behind a near net-shape composite part. Benefits of this process include increased composite uniformity, no mold machining, short time from design to part properties matching traditional methods, ability to make previously impossible to manufacture parts and no size limitations with a newly developed joining technology. The results of materials, manufacturing and design optimizations, preform joining, and sub element tests will be presented.

Shah, Sandeep↗
NASA NTRS2002

Metal Matrix Composite LOX Turbopump Housing Via Novel Tool-less Net-Shape Pressure Infiltration Casting Technology

Metal matrix composites (MMC) offer relatively higher specific strength, specific stiffness, lower coefficient of thermal expansion (CTE) and lower density as compared with conventional alloys. These unique properties make them very attractive for aerospace turbomachinery applications where there is ever increasing emphasis to reduce weight and cost, and to increase engine performance. Through a joint effort between NASA and Metal Matrix Cast Composites, Inc., a complex liquid oxygen (LOX) compatible turbopump housing is being redesigned and manufactured from hybrid (particulate and fibers) Aluminum MMC. To this end, a revolutionary toolless pressure infiltration casting technology is being perfected. Ceramic preforms for the composite are 3-dimensionally printed using a stereolithography file, acquired from a CAD model. The preforms are then invested into a refractory material and pressure infiltrated with liquid metal. After casting, the refractory material is washed away leaving behind a near net-shape composite part. Benefits of this process include increased composite uniformity, no mold machining, short time from design to part, properties matching traditional methods, ability to make previously impossible to manufacture parts and no size limitations with a newly developed joining technology. The results of materials, manufacturing and design optimizations, preform joining, and sub-element tests will be presented.

Shah, Sandeep↗
DOE OSTI2021

Internal insulation and corrosion control of molten chloride thermal energy storage tanks

A chloride-based molten-salt system that uses a ternary blend of MgCl 2 /KCl/NaCl is investigated to provide higher-temperature thermal energy storage capability than conventional nitrate salt-based systems. Despite their high thermal stability and operating temperature, molten chlorides present several challenges, including the design of internal liners to prevent the corrosion and thermal stress of alloy tank shells. This work discusses issues and potential solutions related to containment of molten chloride salt, specifically the optimization of the hot face refractory materials for use as internal liners. Furthermore, three down-selected refractory materials were analyzed with respect to permeation of salt through the material as well as chemical stability during high temperature operation. Through the application of X-ray imaging and electron spectroscopy techniques, highly stable secondary surface phases in equilibrium with the molten salt were identified, as well as time-dependent changes in the salt composition itself.

25 ENERGY STORAGE↗
NASA NTRSDate not supplied

Thermochemical Interactions of Yttria-Stabilized Zirconia and Molten Lunar Regolith Simulants

Oxygen produced from lunar resources through in-situ resource utilization (ISRU) is critical to maintaining a permanent human presence on the lunar surface. Molten regolith electrolysis and carbothermal reduction are two promising ISRU techniques for generating oxygen directly from lunar regolith, which is primarily a mixture of oxide minerals; however, both processes require operating temperatures of 1600C to melt lunar regolith and dissociate the molten oxides. These conditions limit the use of many oxide refractory materials, such as Al2O3 and MgO, due to rapid degradation resulting from reactions between the refractory materials and molten lunar regolith. Yttria-stabilized zirconia (YSZ) is a promising refractory oxide to provide containment of molten regolith while demonstrating limited reactivity. This work focuses on corrosion studies of YSZ powders and dense YSZ crucibles in contact with molten lunar mare and highlands regolith simulants at 1600C. The interactions between YSZ and molten regolith are characterized using SEM/EDS, XRD, and EBSD with an emphasis on elemental and microstructural analysis to assess reactivity and degradation of YSZ. Due to lunar regolith’s similar composition to calcium-magnesium-aluminosilicates (CMAS) and YSZ’s usage as a thermal barrier coating, these interactions can serve to inform YSZ/CMAS behavior by simulating cases of elevated CMAS/YSZ ratios and for higher than intended gas turbine temperatures.

Kevin Yu↗
NASA NTRS1982

Attachment system for silica tiles

An improved method for markedly increasing the bond strength between a rigid, porous refractory material and non-rigid substrate by densifying the face of the rigid material opposing the substrate is discussed. Densification is accomplished by wetting the refractory material and then impregnating it with a composite slurry having a particle size to fill voids of the porous material.

Dotts, R. L.↗
NASA NTRS2024

Thermochemical Interactions Between Yttria-Stabilized Zirconia and Molten Lunar Regolith Simulants

Oxygen produced through in-situ resource utilization (ISRU) is critical to maintaining a permanent human presence on the lunar surface. Molten regolith electrolysis and carbothermal reduction are two promising ISRU techniques for generating oxygen directly from lunar regolith, which is primarily a mixture of oxide minerals; however, both processes require operating temperatures of 1600 C to melt lunar regolith and dissociate the molten oxides. These conditions limit the use of many oxide refractory materials, such as Al2O3 and MgO, due to rapid degradation resulting from reactions between the refractory materials and molten lunar regolith. Yttria-stabilized zirconia (YSZ) is shown here to be a promising refractory oxide to provide containment of molten regolith while demonstrating limited reactivity. This work focuses on corrosion studies of YSZ powders and dense YSZ crucibles in contact with molten lunar maria and highlands regolith simulants at 1600 C. The interactions between YSZ and molten regolith are characterized using SEM/EDS, XRD, and EBSD. A FactSage thermochemical model is created to compare with the experimental results. These combined analyses suggest that lunar maria regolith will degrade YSZ faster than lunar highlands regolith due to the lower viscosity of the maria regolith. The feasibility of long-term molten regolith containment with YSZ is discussed based on the YSZ powder and crucible results.

Kevin Yu↗
NASA NTRS1989

Stochastic histories of dust grains in the interstellar medium

The purpose is to study an evolving system of refractory dust grains within the Interstellar Medium (ISM). This is done via a combination of Monte Carlo processes and a system of partial differential equations, where refractory dust grains formed within supernova remnants and ejecta from high mass loss stars are subjected to the processes of sputtering and collisional fragmentation in the diffuse media and accretion within the cold molecular clouds. In order to record chemical detail, the authors take each new particle to consist of a superrefractory core plus a more massive refractory mantle. The particles are allowed to transfer to and fro between the different phases of the interstellar medium (ISM) - on a time scale of 10(exp 8) years - until either the particles are destroyed or the program finishes at a Galaxy time of 6x10(exp 9) years. The resulting chemical and size spectrum(s) are then applied to various astrophysical problems with the following results. For an ISM which has no collisional fragmentation of the dust grains, roughly 10 percent by mass of the most refractory material survives the rigors of the ISM intact, which leaves open the possibility that fossilized isotopically anomalous material may have been present within the primordial solar nebula. Stuctured or layered refractory dust grains within the model cannot explain the observed interstellar depletions of refractory material. Fragmentation due to grain-grain collisions in the diffuse phase plus the accretion of material in the molecular cloud phase can under certain circumstances cause a bimodal distribution in grain size.

Liffman, Kurt↗
NASA NTRSDate not supplied

On the New Optical Constants Database (OCdb) and its Importance for the Interpretation of Observational Data

The Optical Constants database(ocdb.smce.nasa.gov) came online in February 2023 and provides complex refractive indices of laboratory-generated organic refractory materials and ices relevant to (exo) planetary and astrophysical environments.The goal of the OCdb is to centralize published optical constants data to facilitate both their access by the scientific community and their use to analyze observational data returned by space missions and ground-based observatories. Computational tools are also under development to facilitate scientific use of the available OCdb optical constants data sets. Investigators generating laboratory optical constants are therefore encouraged to contribute their data to OCdb in order to increase the availability of their data and to enhance the scientific effectiveness of the database. Optical constants are critical input parameters in models (e.g.,radiative transfer, atmospheric, and reflectance spectral models)that are used to simulate the absorption, reflection, and scattering of light due to solid materials present in planetary and astrophysical environments (planets, their satellites, exoplanets, asteroids, comets, protoplanetary disks, etc.), and are key to the compositional interpretation of observations. We will first present the infrastructure of the OCdb and show how to use and contribute to it. We will introduce the two large NASA projects, namely, the Laboratory Astrophysics Directed Work Package and the NASA Center for Optical Constants, that have been instrumental in (i) developing the OCdb, (ii) generating planetary-and astrophysics-relevant ices and organic refractory materials from gas and ice irradiation in the laboratory, and (iii) determining their optical constants for inclusion in OCdb. We will also present two studies that are making use of these optical constants to interpret observations of Titan’s atmosphere and Pluto’s surface. These studies show the importance of measuring optical constants of laboratory-generated materials, and their impact on the models used to analyze and interpret astronomical observations. These studies also demonstrate the essential importance of such a database and the need for optical constants of a broad range of materials and wavelengths to enable the scientific community and to maximize the scientific return from space missions (e.g., Cassini, New Horizons, SOFIA, JWST).

The Optical Constants database↗
NASA NTRS1989

Chlorination processing of local planetary ores for oxygen and metallurgically important metals

The use of chlorine to extract, reclaim, and purify metals has attractive possibilities for extraterrestrial processing of local planetary resources. While a complete cyclic process has been proposed for the recovery of metallurgically significant metals and oxygen, herein the chlorination step of the cycle is examined. An experimental apparatus for reacting refractory materials, such as ilmenite, in a microwave induced plasma is being built. Complex equilibria calculations reveal that stable refractory materials can, under the influence of a plasma, undergo chlorination and yield oxygen as a by-product. These issues and the potential advantages for plasma processing in space are reviewed. Also presented is a discussion of the complex equilibria program used in the analysis.

Lynch, D. C.↗