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At least 757 records · Page 42

Materials properties characterization in the most extreme environments

Abstract There is an ever-increasing need for material systems to operate in the most extreme environments encountered in space exploration, energy production, and propulsion systems. To effectively design materials to reliably operate in extreme environments, we need an array of tools to both sustain lab-scale extreme conditions and then probe the materials properties across a variety of length and time scales. Within this article, we examine the state-of-the-art experimental systems for testing materials under extreme environments and highlight the limitations of these approaches. We focus on three areas: (1) extreme temperatures, (2) extreme mechanical testing, and (3) chemically hostile environments. Within these areas, we identify six opportunities for instrument and technique development that are poised to dramatically impact the further understanding and development of next-generation materials for extreme environments. Graphical abstract

Schreiber, Daniel K.↗

Scaling the polymerization of polyaldehydes through continuous flow synthesis

Abstract A plug flow reactor was constructed to scale the synthesis of metastable, phthalaldehyde-based polymers to achieve production rates of 1–2 kg per day. The flow-induced mixing and in-line polymerization quench and precipitation sequences resulted in improved polymer purity and long-term stability compared to the same materials made from a conventional batch process. Cryogenic rheology was used to probe the complex fluid dynamics encountered during the polymerization of PPA homopolymers. It is envisioned that this continuous flow manufacturing approach could be extended to other low ceiling temperature or aldehyde monomer systems to help implement and support a plastic circular economy. Graphical abstract

Schwartz, Jared M.↗

Engineering Scale Drying of Aluminum-Clad Spent Nuclear Fuel: Experiment Report

Engineering-scale tests were performed to evaluate the relative effectiveness of forced gas and vacuum-drying processes on aluminum-clad spent nuclear fuel (ASNF) in preparation for extended dry storage. Drying models were developed to improve confidence in the likely range of conditions at the start of dry storage and to understand the factors most significant to each process. Testing was performed at the Holtec International Forced Helium Dehydration training facility in Camden, New Jersey, by students from the University of South Carolina in collaboration with Idaho National Laboratory. A full-size Type 1a basket, with a full-diameter vessel configuration (based on the Department of Energy standardized canister design), was used in combination with a 10 assembly surrogate ASNF arrangement to provide a proxy for geometry. A resistance heater incorporated in one assembly simulated the influence of 100 W decay heat. This instrumented chamber allowed testing of the removal of bulk water, physisorbed water, and chemisorbed water over a range of operating parameters with either drying process. Thick oxide films were grown on aluminum test plates to mimic the ASNF surface chemistry. These one-use test plates were housed within select assemblies during drying. Post-test analysis of these plates gave a measure of the moisture removed during each test, which was compared to a control. Instrumentation provided detailed thermal, humidity, and gas or pressure data relevant to each test. Model simulations generally compared favorably to instrument data for the tests. While both processes were able to remove bulk water, removal of chemisorbed water was shown to depend heavily on local temperature. To the disadvantage of vacuum drying, operations approaching or exceeding 220°C achieved consistently more dehydroxylation.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Mid Infra-Red Laser Sensor for Continuous Sulfur Trioxide Monitoring to Improve Coal-Fired Power Plant Performance during Flexible Operations

During the course of this project, we performed exhaustive research and development of SO3/H2SO4 sensing technology for coal-fired power plant applications (Figure 1). The development culminated in a successful field campaign of a prototype continuous real-time H2SO4 monitor at a coal-fired power plant (TRL 6) accomplishing the primary goal of the project. The developed sensors utilize tunable laser absorption spectroscopy (TLAS) operating in the mid-infrared (Mid-IR) wavelength region, which is the so-called “molecular fingerprint” region. Systems operating in the Mid-IR have orders of magnitude more sensitivity than systems operating at shorter wavelengths, such as near-infrared (NIR). However, NIR systems are more widespread due to more mature supporting technology (e.g., fiber optics, optical components, etc.). In this project, we not only produced a specific Mid-IR sensor, we also advanced Mid-IR sensor technology in general through the development and demonstration of such supporting technology. In this project, we also developed proprietary broad tuning lasers enabling the ability to effectively measure SO3, H2SO4, H2O, and SO2. Different molecular species have unique spectral signatures that can be probed with lasers operating at different wavelengths. Standard TLAS uses relatively narrow wavelength tuning distributed feedback (DFB) lasers, which can typically only target a single species with narrow features, and are not appropriate for species with broad features, such as SO3 or H2SO4. In contrast, by developing unique, broad-tuning laser technology, we were able to measure these species, as well as SO2 and H2O simultaneously. Furthermore, to enable real-time analysis at a power plant, we modified a commercially available heated gas cell to operate in the Mid-IR wavelength range and fiber coupled the lasers to enable remote delivery of the beams. To generate reference data (library spectra), our collaborators at the University of California Irvine (UCI) developed a catalytic SO3 generation facility. It is worth mentioning that representative H2SO4 and SO3 Mid-IR spectra are not a part of any publicly available database and the data generated under this project is a valuable resource in and of itself. In addition, based on the UCI study we determined that detection of SO3 is complicated by the very strong SO2 absorption. For that reason, we concentrated on H2SO4 detection. Since SO3 and H2SO4 exist in a flue gas in a state of equilibrium, which depends on temperature and humidity, by measuring water concentration and controlling the temperature of the gas cell, we developed an approach to determine SO3 concentration from the H2SO4 measurement. During the development phase of the project, we performed three testing campaigns at our collaborator’s FERCo flue gas facility with conditions representative of the coal-fired power plant (~ 40ppm SO3, 1700ppm to 2800 ppm SO2, 10% water) with the exception of particulate matter. After three test campaigns at FERCo we performed field testing at Harrison Power Station. The final system was mounted on a duct and measured H2SO4, SO2 and water. The tests were highly successful with a demonstrated real-time H2SO4 precision of 1 ppm with a 1 second update. Our collaborators at EPRI conducted an industry survey and determined that there is a very high interest for the SO3/H2SO4 monitoring in the power generation industry as well as in heavy industries in general. Furthermore, work performed by OptoKnowledge beyond the scope of this project under a synergistic DOE SBIR determined another approach to SO3 detection. We applied for Phase II on this SBIR for development a of versatile SO3/H2SO4 sensor but were not selected. We are currently looking for another opportunity to leverage all the technological advancements produced by this project including but not limited to the flue gas facility at UCI, the hardware and software developed, and relationships with FERCo, EPRI CEMTEK, and Harrison Station.

01 COAL, LIGNITE, AND PEAT↗

Self-Healing Cements with Improved Toughness at Casing and Formation Interfaces for Subsurface Applications

The goal of this project (developed for Topic 2) is to demonstrate that PNNL’s self-healing cement (US Patent 20180044570A1) is a superior well construction material compared to conventional cement and to accelerate its commercial adoption. The project also enables a pathway toward a rigorous and reproducible EGS development approach that can be extended to high-temperature unconventional oil and gas reservoirs as well as low temperature carbon storage reservoirs. To achieve this goal, the project’s objectives are to answer remaining technical questions and to address identified technical and market barriers. This project involves collaboration between PNNL, ARE, Cyrq Energy (under the auspices of ARE), and RC. This team demonstrates a strong technical partnership, linking theoretical and laboratory expertise with field-based geothermal resource management and well completions.

36 MATERIALS SCIENCE↗

State-to-State Molecular Reactions in the Ultracold Regime (Final Scientific Report)

We have achieved the proposed goal to experimentally probe the AB + CD and AB + C types of reactions with state-to-state resolution, which we also compared to advanced theoretical calculations to help elucidate the role of quantum mechanics in the processes of bond breakage and formation. Our approach uses reactants that are prepared at ultracold temperatures (< 1µK) such that the quantum effects of translational motion are an important factor. Specific example reactions, including the potassium-rubidium metathesis reaction KRb + KRb → K 2 + Rb 2 as well as the atom exchange reaction Rb + KRb → Rb2 + K, are chosen because the technology of quantum internal and motional state control of these types of molecules is particularly advanced. The results for the entire funding period are fruitful. For the majority of this grant, we have constructed a one-of-the-kind quantum degenerate gas apparatus that integrates ion detection and velocity map imaging capabilities, allowing us to explore the KRb + KRb → K 2 + Rb 2 bimolecular reaction in detail. Specifically, we first verified such a reaction indeed proceed at ultracold temperatures by direct detection of reaction products. We then mapped out the complete product state distribution, which was compared to a state-counting model based on statistical theory. Our results show an overall agreement with the statistical state counting model, but also reveal several deviating state-pairs. An exact quantum calculation for molecule-molecule collisions, that is needed to understand these deviations, is however beyond the current state-of-the-art. Beside scrutinizing the reaction products, we also directly observe the reaction intermediate complex, which was quite a surprise to us. The intermediate complexes are long-lived and can interact with the inferred light that we use to trap the ultracold gas. After molecule-molecule collisions, we then explored the more theoretically tractable Rb + KRb reaction, which is endothermic. Surprisingly, we observed an exceedingly long-lived KRb$^*_2$ collisional complexes, with our experimentally measured complex lifetime deviating from conventional theoretical calculations by five orders of magnitude. This discrepancy has motivated many explorations of possible underlying causes, though no model yet captures this phenomenon completely. In the final year and the work that continues today, we extend upon these atom-molecule collision experiments to explore the origin of the long-lived KRb$^*_2$ complex lifetime and develop means to control the outcome of the reaction complex. The 5-year funded work advanced our understanding of chemical reactions at the lowest possible temperatures and at the same time opened up many new questions that are beyond our initial imaginations.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Low Cost Glass-Ceramic Matrix Composites for Harsh Environment Heat Exchangers (Final Technical Report)

Nearly all high temperature heat exchangers are currently constructed from metallic alloys that can have good capability but are limited to hot inlet temperatures in the range of 1,200 to 1,400 °F. In general, increasing the hot inlet temperature will improve existing application cycles to operate more efficiently, and it will enable new application cycles to be viable that otherwise would not be. The objective of this project was to mature the technologies associated with the development of a ceramic-class heat exchanger that would significantly increase the operating temperature to 1,600 °F and above. The approach taken was to use Glass-Ceramic Matrix Composite (G-CMC) material and to fabricate coupon-scale tube sheet heat exchangers (HXs) to identify risks, refine details of the process and develop a pathway for this novel approach.

36 MATERIALS SCIENCE↗

Synthesis of Lanthanide-Based Intermetallic Silicides

Lanthanide-containing materials are of interest because of their useful magnetic and electronic behavior. To study this intrinsic behavior, researchers need high-quality single crystals to avoid interference from grain boundaries or defects commonly found in polycrystalline samples. One method for growing single crystals is metal-flux synthesis, an approach that promotes crystal growth at lower reaction temperatures thus providing access to complex intermetallic phases. My project focuses on synthesizing novel lanthanide-containing intermetallic silicides related to previously reported f-element compounds with the Gd1??Fe4Si10?? structure type. I investigated reactions targeting lanthanum, praseodymium, neodymium, samarium, europium, and gadolinium-containing products, and used scanning electron microscopy with energy-dispersive X-ray spectroscopy (SEM-EDS) to identify promising lanthanide-containing phases. I prepared reactions by loading lanthanide oxides, Co, Si, Al, and Ga into alumina crucibles in a 0.2:1:1:10:10 Ln2O3/Co/Si/Al/Ga mmol ratio, where Ln = La, Nd, Pr, Sm, Eu, or Gd. The reactions were sealed in quartz tubes, heated in a furnace, and centrifuged to separate crystals from excess flux. Afterwards, I mechanically isolated single crystals and prepared them for characterization. Pr-, Nd-, and Sm-containing reactions were confirmed through SEM-EDS to have formed the targeted quaternary phase. Single crystal X-ray diffraction (SC-XRD) data showed the Nd-containing crystals exhibited a hexagonal unit cell associated with the Gd1??Fe4Si10?? structure type. La- and Eu-containing reactions instead formed competing Co(Al/Ga/Si)3 phase crystals. Single-crystal XRD, powder XRD, and magnetic susceptibility and heat-capacity measurements will be collected for the remaining lanthanide-containing crystals. This data will help determine the complete crystal structure of the lanthanide analogues, their phase purity and whether they exhibit localized magnetic behavior, magnetic ordering, or other electronic signatures that can be compared with the previously reported actinide analogues. The disordered structure of this intermetallic family is associated with unusual magnetic and electronic behavior meaning lanthanide analogues may show potential as thermoelectric materials. Developing new thermoelectric candidate materials is relevant to energy efficiency and waste-heat recovery, which supports DOE’s broader goal of advancing science and technology solutions for America’s energy needs.

37 - INORGANIC, ORGANIC, PHYSICAL AND ANALYTICAL C↗

Detection and Bulk Properties of the HR 8799 Planets with High-resolution Spectroscopy

Using the Keck Planet Imager and Characterizer, we obtained high-resolution (R ~ 35,000) K-band spectra of the four planets orbiting HR 8799. We clearly detected H{sub 2}O and CO in the atmospheres of HR 8799 c, d, and e, and tentatively detected a combination of CO and H{sub 2}O in b. These are the most challenging directly imaged exoplanets that have been observed at high spectral resolution to date when considering both their angular separations and flux ratios. We developed a forward-modeling framework that allows us to jointly fit the spectra of the planets and the diffracted starlight simultaneously in a likelihood-based approach and obtained posterior probabilities on their effective temperatures, surface gravities, radial velocities, and spins. We measured vsin (i) values of 10.1{sub -2.7}{sup +2.8} km s{sup -1} for HR 8799 d and 15.0{sub -2.6}{sup +2.3} km s{sup -1} for HR 8799 e, and placed an upper limit of <14 km s{sup -1} of HR 8799 c. Under two different assumptions of their obliquities, we found tentative evidence that rotation velocity is anticorrelated with companion mass, which could indicate that magnetic braking with a circumplanetary disk at early times is less efficient at spinning down lower-mass planets.

74 ATOMIC AND MOLECULAR PHYSICS↗

Power Electronics Materials and Bonded Interfaces - Reliability and Lifetime

High temperature operation of wide bandgap devices continue to be a challenge for the power electronics packages. Thermal performance and reliability are important factors that determine the viability of a bonded interface for operation at high temperatures. In this presentation, we present the technical approach and key results from the research on sintered silver, transient liquid phase alloy, and polymeric materials. A lifetime prediction model that incorporates the thermomechanical behavior of sintered silver at 200C was developed. The copper-aluminum transient alloy completed 350 thermal cycles from -40C to 200C and little increase in the defect level was observed. In addition to material research, we initiated a time-series analysis on the scanning acoustic microscope images of eutectic solder to explore statistical forecasting methods and machine learning techniques. Initial results that report the accuracy of a few different statistical models are presented.

ADVANCED PROPULSION SYSTEMS↗

Global Evaluation of Process Conditions and Wave Modes in a Rotating Detonation Engine

Rotating Detonation Engines (RDEs) show significant promise for enhancing the efficiency of gas turbine engines while maintaining low 𝑁𝑂𝑥 emissions. This work investigates the predictability of wave modes in a water-cooled RDE under varying operational conditions. Experimental data comprising over 6,700 samples was collected, including parameters such as flow rates, temperatures, pressures, and equivalence ratios. A machine learning approach using the XGBoost library was used to build a multi-class classifier, predicting wave modes based on these inputs. The model achieved a high accuracy of 97%, demonstrating that wave modes are not random but deterministic based on the process conditions. SHAP analysis was used to identify the most influential parameters affecting wave mode prediction. The results show that for the water-cooled NETL RDE, wave mode is determinant and predictable based on the process parameters.

Weber, Justin [NETL] (ORCID:0000000218487035)↗

Solvent-Mediated, Reversible Ternary Graphite Intercalation Compounds for Extreme-Condition Li-Ion Batteries

Traditional Li-ion intercalation chemistry into graphite anode exclusively utilizes the co-intercalation-free or co-intercalation mechanism. The latter mechanism is based on ternary graphite intercalation compounds (t-GICs), where glyme solvents were explored and proved to deliver unsatisfied cyclability in LIBs. Herein, we report a novel intercalation mechanism, that is, in-situ synthesis of t-THF-GICs in the tetrahydrofuran (THF) electrolyte via a spontaneous, controllable reaction between binary-GICs and free THF molecules during initial graphite lithiation. The spontaneous transformation from b-GIC to t-GIC, which is different from conventional co-intercalation chemistry, is characterized and quantified via operando synchrotron X-ray and electrochemical analyses. The resulting t-GIC chemistry obviates the necessity for complete Li-ion desolvation, facilitating rapid kinetics and synchronous charge/discharge of graphite particles even under high current densities. Consequently, the graphite anode demonstrates unprecedented fast charging (1 min), dendrite-free low-temperature performance, and ultralong lifetimes exceeding 10,000 cycles. Full cells coupled with layered cathode, display remarkable cycling stability upon a 15-min charging and excellent rate capability even at -40 °C. Furthermore, our chemical strategies are shown to extend beyond Li-ion batteries to encompass Na-ion and K-ion batteries, underscoring their broad applicability. Our work contributes to the advancement of graphite intercalation chemistry and presents a low-cost, adaptable approach to achieving fast-charging and low-temperature batteries.

25 ENERGY STORAGE↗

Mechanistic calculation of the effective silver diffusion coefficient in polycrystalline silicon carbide: Application to silver release in AGR-1 TRISO particles

The silicon carbide (SiC) layer in tristructural isotropic (TRISO) fuel particles serves as a barrier to prevent the escape of fission products produced and not retained in the fuel kernel. The release of silver (Ag) is a concern due to the long half-life of the 110m Ag isotope. However, accurately determining the fission gas release rate requires knowing the diffusion coefficient through the SiC layer. In this study, we leverage atomistic calculations of Ag diffusivity in SiC bulk and grain boundaries (GBs) to develop a mesoscale effective Ag diffusion coefficient (D eff ) in SiC. Since GBs serve as pathways for Ag diffusion, D eff is defined as a function of temperature and microstructure variables. In particular, the size of SiC grains in the direction perpendicular to diffusion is shown to significantly affect Ag diffusion. The prediction of the mechanistic, mesoscale approach falls within one order of magnitude of empirical values. The temperature and microstructure-dependent effective Ag diffusivity in SiC is implemented in the fuel performance code Bison with a correction factor to predict Ag release from AGR-1 TRISO fuel particles. We hereby quantify the impact of SiC grain size on Ag release and improve Bison’s predictions.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Multiscale Electrothermal Design of a Modular Multilevel Converter for Medium-Voltage Grid-Tied Applications

As a key feature of modular multilevel converters (MMCs), a large number of semiconductor devices are employed in the converter and distributed over a stack of submodules. Each submodule has a strict temperature limit that imposes constraints on the operating range of the converter. Different loading conditions/losses in the submodules lead to unavoidable temperature variations inside the MMC, which consequently affect the system-level performance and reliability. This paper is focused on the electrothermal analysis and design of a medium-voltage silicon carbide (SiC)-based MMC system, from submodule power semiconductors to the overall MMC system integration of multiple submodules, for grid-connected applications. Loss calculations are performed to estimate the cooling requirements and aid thermal design at different levels. The performance of a forced-air cooling approach is analyzed within a numerical modeling framework. Maximum temperature of the SiC power modules is predicted using numerical tools. Thermal design of the MMC cabinet with various arrangements of air inlet(s) and outlet(s) is investigated and compared from a cooling performance perspective. A fully resolved model of the arrangement that yields optimal results is developed to accurately predict the temperature profile of the essential components in the submodules.

computational fluid dynamics↗

Revisiting the structures and phase transitions of Ba 2 NaNb 5 O 15

The room-temperature and low-temperature structure(s) of Ba 2 NaNb 5 O 15 (BNN) have been debated since the structure was proposed in the 1960s. This work revisits the structures and phase transitions of BNN, combining high-resolution X-ray and neutron powder diffraction with density functional theory calculations. Temperature-dependent high-resolution X-ray powder diffraction patterns are collected from 4 to 918 K, and sequential batch Rietveld refinement using a symmetry mode approach to describe the structure is used to extract the main structural changes as a function of temperature. The data show that the average structure of BNN is best described by the Ama2 space group, and no other structural phase transitions were observed below the ferroelastic transition. The symmetry mode analysis, combining results from diffraction and density functional theory, shows significant octahedral tilting and corrugations of both the A1 and A2 sites along the c direction. A strong correlation between the spontaneous strain and the octahedral tilting was observed, and a potential connection with emerging microstructure at low temperatures is proposed, all enabled by the symmetry mode approach used in this work.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Scalable Bottom-Up Synthesis of Nanoporous Hexagonal Boron Nitride ( h -BN) for Large-Area Atomically Thin Ceramic Membranes

Nanopores embedded within monolayer hexagonal boron nitride (h-BN) offer possibilities of creating atomically thin ceramic membranes with unique combinations of high permeance (atomic thinness), high selectivity (via molecular sieving), increased thermal stability, and superior chemical resistance. However, fabricating size-selective nanopores in monolayer h-BN via scalable top-down processes remains nontrivial due to its chemical inertness, and characterizing nanopore size distribution over a large area remains extremely challenging. Here, we demonstrate a facile and scalable approach of exploiting the chemical vapor deposition (CVD) process temperature to enable direct incorporation of subnanometer/nanoscale pores into the monolayer h-BN lattice, in combination with manufacturing compatible polymer casting to fabricate centimeter-scale nanoporous atomically thin ceramic membranes. We leverage diffusive transport of analytes including size-selective Ficoll sieving to characterize subnanometer-scale and nanoscale defects that manifest as pores in centimeter-scale h-BN membranes, overcoming previous limitations in large-area characterization of nanoscale defects in h-BN. Our approach opens a new frontier to advance atomically thin membranes to 2D ceramic materials, such as h-BN via facile and direct formation of nanopores, for size-selective separations.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Implementation of the Windowed Multipole Method in Shift

The windowed multipole (WMP) method has been implemented in the Shift Monte Carlo (MC) radiation transport code with support for both CPU and GPU execution. With this method, small WMP data libraries (~100 MB) can be used to accurately Doppler broaden cross sections to arbitrary temperatures “on the fly” during an MC simulation. This approach yields significant memory savings relative to traditional methods, making it ideal for high-fidelity analysis such as coupled multiphysics simulations. This document provides the exact forms of the WMP equations used by Shift, as well as a detailed description of the structure of WMP HDF5 data files provided by the Massachusetts Institute of Technology (MIT). The Shift implementation has been validated against the OpenMC radiation transport code, with excellent agreement demonstrated for 70 nuclides across an operative range of temperatures. CPU and GPU performance testing using a small module reactor (SMR) problem demonstrated that this method decreases the neutron tracking rate by a factor of ~2 on the Summitdev machine. A new set of WMP data being developed in-house will employ novel methods to improve tracking rates.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

Reducing Antisolvent Use in the STRAP Process by Enabling a Temperature–Controlled Polymer Dissolution and Precipitation for the Recycling of Multilayer Plastic Films

The recently reported processing strategy called solvent-targeted recovery and precipitation (STRAP) enables deconstruction of multilayer plastic packaging films into their constituent resins by selective dissolution. It uses a series of solvent washes that are guided by thermodynamic calculations of polymer solubility. In this work, the use of antisolvents in the STRAP process was reduced and solvent mixtures were considered to enable the temperature-controlled dissolution and precipitation of the target polymers in multilayer films. This was considered as a means to further improve the STRAP process and its estimated costs. Two STRAP approaches were compared based on different polymer precipitation techniques: precipitation by the addition of an antisolvent (STRAP-A) and precipitation by decreasing the solvent temperature (STRAP-B). Both approaches were able to separate the constituent polymers in a post-industrial film composed primarily of polyethylene (PE), ethylene vinyl alcohol (EVOH), and polyethylene terephthalate (PET) with near 100 % material efficiency. Technoeconomic analysis indicates that the minimum selling price (MSP) of the recycled resins with STRAP-B is 21.0 % lower than that achieved with STRAP-A. This provides evidence that thermally driven polymer precipitation is an option to reduce the use of antisolvents, making the STRAP process more economically and environmentally attractive. A third process, STRAP-C, was demonstrated with another post-industrial multilayer film of a different composition. Here, the results demonstrate that this process can also recover polymers at similar costs to those of virgin resins, indicating that the STRAP technology is flexible and can remain economically competitive as the plastic feed complexity is increased.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗