Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “CORROSIVE”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 865 records · Page 48
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Inexpensive and Sustainable Anti-Corrosion Coating for Power Generation Applications

The goal of the project was to achieve lab-scale demonstration of a corrosion prevention technology, which will facilitate the capture of CO 2 from coal and natural gas fired power generation by reducing the cost of construction materials and maintenance. The project built on technology previously developed by LumiShield to address more broad-based corrosion issues and the results shown will be applicable to a wide range of markets requiring cost effective corrosion resistant coatings. That technology developed is a base layer to improve the performance and reduce the cost of organic anti-corrosion coatings. The impact of those changes on overall plant economics were demonstrated with the help of engineers at AECOM through an initial cost-benefit-analysis at the end of BP1 which will be updated at the end of BP2.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

Effect of Microstructural Bands on the Localized Corrosion of Laser Surface-melted 316L Stainless Steel

The localized corrosion of laser surface melted (LSM) 316L stainless steel is investigated by a combination of potentiodynamic anodic polarization in 0.1M HCl and microscopic investigation of the initiation and propagation of localized corrosion. The pitting potential of LSM 316L is significantly lower than the pitting potential of wrought 316L. The LSM microstructure is highly banded as a consequence of the high laser power density and high linear energy density. The bands are composed of zones of changing modes of solidification, cycling between very narrow regions of primary austenite solidification and very wide regions of primary ferrite solidification. Pits initiate in the outer edge of each band where the mode of solidification is primary austenite plane front solidification and primary austenite cellular solidification. The primary austenite regions have low chromium concentration (and possibly low molybdenum concentration), which explains their susceptibility to pitting corrosion. The ferrite is enriched in chromium, which explains the absence of pitting in the primary ferrite regions. The presence of the low chromium regions of primary austenite solidification explains the lower pitting resistance of LSM 316L relative to wrought 316L. The influence of banding on localized corrosion is applicable to other rapidly solidified processes such as additive manufacturing.

36 MATERIALS SCIENCE↗
DOE OSTI2022

(Project 18-15531) Repair and Mitigation of Chloride-Induced Pitting and Chloride-Induced Stress Corrosion Cracking in Used Spent Nuclear Fuel Dry Cask Canister Materials (Final Technical Report)

Several experimental techniques were utilized to understand the corrosion and SCC performance of possible techniques for repairing cracks and pits in SS304 utilized for dry cask storage of spent nuclear fuel. The repairs examined included cold spray, FSW, soldering, and VFAW. The corrosion and SCC assessment techniques utilized for comparing repairs against the base material were 4-pt bending SCC testing in boiling MgCl 2 at stress levels between 0 MPa and 350 MPa, immersion testing in 40% RH brine solution meant to mimic a service-like environment, SSRT SCC testing in 40% RH brine solution. For FSW alone, scanning electrochemical cell microscopy and microelectrochemical syringe cell were utilized to understand the corrosion performance across the weld, in the retreating/advancing sides, and base material. Based on the results of this study, the FSW and cold spray repair techniques proved most viable for SCC repair in SS304 dry cask storage applications and continuing research is highly recommended to understand and quantify in further detail their SCC performance compared to unrepaired SS304. Additionally, solder and VFAW (patch or incline) would not be recommended based on the corrosion and SCC findings in this study.

42 ENGINEERING↗
DOE OSTI2025

Corrosion and Mechanical Durability Testing in High Temperature Molten Sulfur (CRADA Final Report)

The overall goal of the project is to explore and identify suitable candidate materials for high-temperature molten sulfur thermal energy storage (TES) operating up to a maximum temperature of 400°C–420°C for industrial process heat applications. A detailed corrosion and strength analysis of coupons subjected to long-term thermal testing in molten sulfur will be conducted to characterize the fundamental corrosion mechanism, corrosion rates, and mechanical durability. The results from the project contribute to the engineering design of sulfur TES systems with desired longevity and lower construction and maintenance costs. The research outcome benefits the TES research and development community by providing detailed corrosion and degradation information for more effective engineering design of the molten sulfur TES containment. It improves the diversity and reliability of the renewable technologies available for the U.S. industries and U.S. power grid.

14 SOLAR ENERGY↗
DOE OSTI2025

Hanford Double Shell Waste Tank Corrosion Studies- Final Report FY2024

For fiscal year (FY) 2024, the Savannah River National Laboratory (SRNL) focused on two experimental tasks related to Hanford Double Shell Tank (DST) chemistry and integrity. The first task focused on understanding risk of corrosion due to formation of either continuous layers or discrete patches of solids on the tanks’ inner sidewalls and bottoms. The objective of this task was to determine the effect of solid deposits on the corrosion risk to the tank bottom, and whether a combination of scale, saltcake and loose solids lead to under deposit corrosion. Electrochemical testing in a single cell arrangement was employed to determine a threshold inhibitor level for the interstitial liquid in the solids, above which carbon steel was not susceptible to corrosion beneath the solids. The inhibitor levels tested were based on the previously determined probability of failure for carbon steel in a simulated waste (i.e., Pitting Factor).

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

An Impedance-Loaded Surface Acoustic Wave Corrosion Sensor for Infrastructure Monitoring

Passive surface acoustic wave (SAW) devices are attractive candidates for continuous wireless monitoring of corrosion in large infrastructures. However, acoustic loss in the aqueous medium and limited read range usually create challenges in their widespread use for monitoring large systems such as oil and gas (O&G) pipelines, aircraft, and processing plants. This paper presents the investigation of impedance-loaded reflective delay line (IL-RDL) SAW devices for monitoring metal corrosion under O&G pipeline-relevant conditions. Specifically, we studied the effect of change in resistivity of a reflector on the backscattered signal of an RDL and investigated an optimal range through simulation. This was followed by the experimental demonstrations of real-time monitoring of Fe film corrosion in pressurized (550 psi) humid CO 2 conditions. Additionally, remote monitoring of Fe film corrosion in an acidic solution inside a 70 m carbon steel pipe was demonstrated using guided waves. This paper also suggests potential ways to improve the sensing response of IL-RDLs.

47 OTHER INSTRUMENTATION↗
DOE OSTI2024

Near-Field Passive Wireless Sensor for High-Temperature Metal Corrosion Monitoring

This work focuses on the fabrication and evaluation of a passive wireless sensor for the monitoring of the temperature and corrosion of a metal material at high temperatures. An inductor–capacitor (LC) resonator sensor was fabricated through the screen printing of Ag-based inks on dense polycrystalline Al 2 O 3 substrates. The LC design was modeled using the ANSYS HFSS modeling package, with the LC passive wireless sensors operating at frequencies from 70 to 100 MHz. The wireless response of the LC was interrogated and received by a radio frequency signal generator and spectrum analyzer at temperatures from 50 to 800 °C in real time. The corrosion kinetics of the Cu 110 was characterized through thermogravimetric (TGA) analysis and microscopy images, and the oxide thickness growth was then correlated to the wireless sensor signal under isothermal conditions at 800 °C. The results showed that the wireless signal was consistent with the corrosion kinetics and temperature, indicating that these two characteristics can be further deconvoluted in the future. In addition, the sensor also showed a magnitude- and frequency-dependent response to crack/spallation events in the oxide corrosion layer, permitting the in situ wireless identification of these catastrophic events on the metal surface at high temperatures.

36 MATERIALS SCIENCE↗
NASA NTRS2003

An evaluation of microbial growth and corrosion of 316L SS in glycol/seawater mixtures

Glycol/seawater mixtures containing > 50% glycol inhibit corrosion of 316L stainless steel and do not support bacterial growth. The results indicate bacteria are able to use low concentrations of glycol (10%) as a growth medium, but bacterial growth decreased with increasing glycol concentration. Pitting potential, determined by anodic polarization, was used to evaluate susceptibility of 316L SS to corrosion in seawater-contaminated glycol. Mixture containing a minimum concentration of 50% propylene glycol-based coolant inhibited pitting corrosion. A slightly higher minimum concentration (55%) was needed for corrosion protection in ethylene glycol mixtures.

Biofilms/growth & development↗
NASA NTRS2017

Coatings for Oxidation and Hot Corrosion Protection of Disk Alloys

Increasing temperatures in aero gas turbines is resulting in oxidation and hot corrosion attack of turbine disks. Since disks are sensitive to low cycle fatigue (LCF), any environmental attack, and especially hot corrosion pitting, can potentially seriously degrade the life of the disk. Application of metallic coatings are one means of protecting disk alloys from this environmental attack. However, simply the presence of a metallic coating, even without environmental exposure, can degrade the LCF life of a disk alloy. Therefore, coatings must be designed which are not only resistant to oxidation and corrosion attack, but must not significantly degrade the LCF life of the alloy. Three different Ni-Cr coating compositions (29, 35.5, 45wt. Cr) were applied at two thicknesses by Plasma Enhanced Magnetron Sputtering (PEMS) to two similar Ni-based disk alloys. One coating also received a thin ZrO2 overcoat. The coated samples were also given a short oxidation exposure in a low PO2 environment to encourage chromia scale formation. Without further environmental exposure, the LCF life of the coated samples, evaluated at 760C, was less than that of uncoated samples. Hence, application of the coating alone degraded the LCF life of the disk alloy. Since shot peening is commonly employed to improve LCF life, the effect of shot peening the coated and uncoated surface was also evaluated. For all cases, shot peening improved the LCF life of the coated samples. Coated and uncoated samples were shot peened and given environmental exposures consisting of 500 hrs of oxidation followed by 50 hrs of hot corrosion, both at 760C). The high-Cr coating showed the best LCF life after the environmental exposures. Results of the LCF testing and post-test characterization of the various coatings will be presented and future research directions discussed.

LCF life↗
DOE OSTI2011

Corrosion-resistant multilayer coatings for the 28-75 nm wavelength region

Corrosion has prevented use of SiC/Mg multilayers in applications requiring good lifetime stability. We have developed Al-based barrier layers that dramatically reduce corrosion, while preserving high reflectance and low stress. The aforementioned advances may enable the implementation of corrosion-resistant, high-performance SiC/Mg coatings in the 28-75 nm region in applications such as tabletop EUV/soft x-ray laser sources and solar physics telescopes. Further study and optimization of corrosion barrier structures and coating designs is underway.

36 MATERIALS SCIENCE↗
DOE OSTI2012

Corrosion Studies Of Raw And Treated Biomass-Derived Pyrolysis Oils

Rapid pyrolysis of biomass generates a liquid with properties that are particularly attractive for production of hydrocarbons that could be substituted for liquid fuels derived from petroleum. However, the high oxygen content of the biomass derived liquids presents a number of problems because of the high water content and the considerable concentration of carboxylic acids. Measurements of total acid number (TAN) of pyrolysis oil (bio-oil) samples show that values in the 90-100 range are fairly common. This level of acidity has been shown to cause corrosion problems that have to be addressed in the selection of structural materials that are used in the production, subsequent processing, storage and transport of the pyrolysis oils. Chemical analyses have been performed and laboratory corrosion studies have been conducted in order to assess the aggressiveness of the raw pyrolysis oil from several sources as well as the corrosion caused by a bio-oil that has been treated to reduce the acid and oxygen content. Components of biomass pyrolyzers have also been fabricated from various candidate alloys, and these components have been exposed for extended periods during operation of the pyrolyzers. This paper will report on results of these analyses and corrosion studies.

02 PETROLEUM↗
DOE OSTI2012

CORROSIVITY AND COMPOSITION OF RAW AND TREATED PYROLYSIS OILS

Fast pyrolysis offers a relatively low cost method of processing biomass to produce a liquid product that has the potential for conversion to several types of liquid fuels. The liquid product of fast pyrolysis, known as pyrolysis oil or bio-oil, contains a high oxygen content primarily in the form of water, carboxylic acids, phenols, ketones and aldehydes. These oils are typically very acidic with a Total Acid Number that is often in the range of 50 to 100, and previous studies have shown this material to be quite corrosive to common structural materials. Removal of at least some of the oxygen and conversion of this oil to a more useful product that is considerably less corrosive can be accomplished through a hydrogenation process. The product of such a treatment is considered to have the potential for blending with crude oil for processing in petroleum refineries. Corrosion studies and chemical analyses have been conducted using as produced bio-oil samples as well as samples that have been subjected to different levels of oxygen removal. Chemical analyses show treatment affected the concentrations of carboxylic acids contained in the oil, and corrosion studies showed a positive benefit of the oxygen removal. Results of these studies will be presented in this paper.

bio-oil↗
DOE OSTI2023

Carbon Corrosion in CO2 Electrolysis Systems

Driven by concerns over climate change, interest in CO2 conversion technologies has dramatically increased in recent years. By viewing CO2 as a readily available feedstock, many pathways for the production of carbon-neutral fuels and chemicals become available. In converting CO2, low carbon emitting energy sources must be used to ensure a low carbon footprint of the fuel and chemical products. The low-temperature electrochemical conversion of CO2 is a promising technology and allows for direct integration with renewable electricity sources. The development of low-temperature CO2 electrolysis technologies is informed by both PEM fuel cells and water electrolyzers, both of which are at a higher stage of development. However, CO2 electrolysis operates at a much higher cell voltage (-3V) than other low-temperature electrochemical processes, which can have implications for materials compatibility in the electrolyzer device. Carbon corrosion is of particular concern for the anode of CO2 electrolyzers, as a large driving force for corrosion exists due to the high required cell potentials. In this presentation, recent observations will be shared on carbon corrosion of the anode gas diffusion electrode (GDE) in low-temperature alkaline exchange membrane CO2 electrolysis. Results from ex-situ tests designed to isolate the carbon corrosion process for anode GDEs will be shared. These results will provide guidance on materials selection for CO2 utilization MEAs, which need to have a lifetime of several years to ensure industrial viability.

BIOMASS FUELS↗
DOE OSTI2020

Erosion-Corrosion Detection in Carbon Steel Pipe Loops using SRNLs Thickness and Mass Loss Measurement Coupons - 20464

Structural health of waste transfer infrastructure is of utmost importance to DOE and communities surrounding their active sites. A Fitness-for-Service (FFS) program for the Waste Transfer System has been implemented by the US Department of Energy (DOE) for the purposes of evaluating and quantifying the degradation of critical components. Currently, the method of approach is to section and evaluate pipelines that have been removed at end service. In order to augment data collection methods applied to making lifespan estimates of waste transfer system components, Florida International University (FIU) has been investigating new-technology based strategies for quantifying the rate of degradation. Present research considers the option of a coupon system installed on a section of pipe at points of interest that will provide easy access to high resolution measurements of erosion/corrosion rates during operation. Researchers at Savannah River National Laboratory (SRNL) have developed this novel solution for in situ erosion and corrosion measurements in many applicable locations such as tanks, pipes, ducts, and injection points. The coupons are approximately 12.7 mm (1/2 inch) in diameter and 25.4 mm (1 inch) in length and can be placed in the pipe sections using Swagelok compression fittings. The coupon design allows for monitoring of the total degradation resulting from corrosion and erosion. High-resolution Ultrasonic Thickness (UT) testing allows in-situ monitoring of both degradation mechanisms. When removed from the system mass loss resulting from corrosion and erosion may also be evaluated. Experimental testing at FIU implemented the SRNL coupon system in a 6.10 meter (20 foot) pipe loop system comprised of 50.8 mm (2 inch) and 76.2 mm (3 inch) pipe sections in order to replicate expected use cases at the sites. Operational conditions were emulated by pumping abrasive materials through the pipeline at full capacity and collecting measurements from the SRNL coupons. Initial testing was conducted by circulating water followed by a mixture of sand and water for uniform wear rates. Thickness changes and mass loss were measured, and the surface exposed to the process fluid was observed for visual evidence of characteristic wear patterns resulting from an erosive environment. The test matrix consisted of several hours of operation and using fine, medium and coarse grain sands. Test results were analyzed to check for all three parameters (mass loss/gain, thickness change and surface patters) which could provide estimates of the remaining useful life of the pipe sections. Thus, the research presents the findings of this evaluation of the SRNL coupons as a means for conducting high accuracy, cost effective in-situ analysis of pipeline and waste transfer systems for erosion and corrosion susceptibility. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2016

Estimating the Penetration Depth and Orientation of Stress Corrosion Cracks Using Time-Reversal Acoustics

Austenitic stainless steels are known to be susceptible to stress corrosion cracking (SCC), which is an aggressive type of corrosion that exists when a material under tensile stress is placed in a corrosive environment. This is of particular concern as the processing (i.e., cold rolling) and construction (welding) of storage canisters produce an inherent residual stress in metals that can lead to SCC. In this context, our objective is to study the formation of stress corrosion cracks within Type 304L stainless steel, which is frequently used in containers for used nuclear fuel disposal. The conditions present in storage canisters (i.e., elevated temperatures, high residual stresses near welds, and exposure to humidity and chloride) make them susceptible to SCC, potentially leading to critical through-wall failure, and thus loss of containment. The timescales on which through-wall failure is expected in a storage canister under typical conditions is on the order of tens of years. While through-wall flaws are catastrophic (e.g., release of helium and fission gases), the long timescales allow for routine inspection, and potentially mitigation, providing methods exist. This paper is focused on the former problem, i.e. detection of SCC, and the development of a tool for inspection of storage canisters. We will discuss the recent work we did on detecting the presence of SCC as well as imaging on its orientation and penetration depth using an acoustic technique developed at Los Alamos National Laboratory (LANL). This technique has been applied successfully in the laboratory on stainless steel samples with SCC provided by General Electric (GE) and the Electric Power Research Institute (EPRI). Recently, we have also demonstrated that this technique can be deployed for field inspections in tight and confined spaces. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2017

Microstructure of In-Core Molten Salt Corrosion Hastelloy N{sup R} and 316 Stainless Steel

Since 2011, many materials have been discussed for potential application in Fluoride salt-cooled High-temperature nuclear Reactors (FHRs), which are emerging as leading reactor concept for the next generation of nuclear reactors thanks to the benefits of a high degree of passive safety, high thermal efficiency, and low spent fuel volume. Among these discussed materials, Hastelloy N{sup R} and 316L stainless steel have been selected as the most likely candidate alloys for FHRs. To provide direct experience in integrating a real system using molten FLiBe salt for reactor operation, these two candidate alloys were experimentally tested in Li-7 enriched Li{sub 2}BeF{sub 4} (FLiBe) molten salt in the core of MIT Research Reactor (MITR) at 700 deg. C for 1000 hours. After in-core corrosion testing, some basic post-irradiation examinations (PIE) including weight change per unit area and surface profile as well as surface morphology were conducted in the MIT Nuclear Reactor Laboratory (NRL) and compared with out-of-reactor corrosion samples. The deep understanding of these alloys in high-temperature molten salt with strong neutron irradiation requires further microstructural analysis such as electron microscopy and energy dispersive spectroscopy on the surface and cross-section of the in-core corrosion tested samples. The challenge in the microstructural analysis is due to the high radioactivity from the gamma emitting isotopes formed in alloys during neutron irradiation. Additionally, the facilities that are authorized for radioactive materials are very limited on campus. In this study, the microstructure of the in-core corrosion tested Hastelloy N{sup R} and 316L stainless steel specimen was analyzed by using the facilities at the Center for Advanced Energy Studies (CAES) at Idaho National Laboratory (INL) through the Nuclear Science User Facilities (NSUF) Rapid Turnaround Experiment (RTE) program.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Multi-Modal Characterization of Interfacial Corrosion of Ni-based Alloys in Chloride-based Molten Salts

The United States Department of Energy (DOE) is committed to the advancement of nuclear reactor technology through initiatives such as the Advanced Reactor Development Program (ARDP), to diversify the United States energy portfolio towards more sustainable energy options. The ARDP includes demonstration by industry partners of molten salt fast reactors (MSRs). Construction of molten salt reactor technology requires qualified nuclear structural materials. Unfortunately, there are no current materials that meet current qualification requirements dictated by the Nuclear Regulatory Commission for construction of MSRs. Adapting current structural material qualifications requires expansion of our current knowledgebase on corrosion performance. In this investigation, we assess microstructural changes in a Ni-based superalloy after exposure to a chloride-containing salt system through a correlated multi-modal approach combining several advanced characterization techniques. Namely we will highlight the impact of grain boundary phenomena at the onset of corrosion attack, including the role of intergranular crack propagation and development of internal corrosion products. The findings from this investigation will further expand our assessment of the corrosion performance of structural materials being investigated for construction of MSR components.

36 - MATERIALS SCIENCE↗
DOE OSTI2017

Corrosion Behavior of Fe-40at.%Al-Based Intermetallic in 0.25 M H{sub 2}SO{sub 4} Solution

The electrochemical behavior of Fe-40at.%Al-based intermetallic microalloyed with 3 and 5 at.% Cu additions in 0.25 M H{sub 2}SO{sub 4} solution over time was studied. A complementary study to characterize the surface morphology and semiquantitative chemical analysis of the corrosion products after 24 h of immersion was performed using scanning electron microscopy and x-ray energy dispersion spectrum. By means of electrochemical techniques, it was shown that Cu addition has a positive effect on corrosion resistance of Fe-40at.%Al-based intermetallic alloy. Additionally, the relatively high concentration of Cu consolidated the passive film of corrosion products and its stability.

36 MATERIALS SCIENCE↗