COMPATIBILITY OF MOLTEN URANIUM DIOXIDE WITH FIVE REFRACTORY MATERIALS
Compatibility of molten uranium dioxide with refractory metals
REFRACTORY METAL↗
SEARCH · Engineering Papers
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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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Early Results from a Broad Compatibility Study of Various Materials with Ionic Silver Biocide
Ionic silver is baselined for microbial control in spacecraft potable water systems forfuture exploration missions, but materials compatibility analysis is required to evaluate thepassive depletion of ionic silver concentration onto wetted material surfaces over time.Various articles concerning such testing have been published that examine interactions withwater containing ionic silver biocide, but most tests have focused on only a couple ofmaterials each and comparing results of different evaluations to one another has provedchallenging.This paper reports the first results from static exposure testing of a large arrayof material coupons to a 400 parts per billion (ppb) aqueous silver fluoride (AgF) solution,using a surface to volume ratio of approximately 2 cm-1. The test is designed in two mainstages. Stage 1 is a one-week screening to evaluate silver uptake. Materials that performmodestly to well after that week are promoted to Stage 2, which is a longer test with periodicsampling to examine the silver uptake rates over time; these samples are evaluated for otherwater quality parameters in addition to the remaining silver concentration. In a tangentialinvestigation, select materials that take up some silver in Stage 1 may be “aged” by repeatingthe Stage 1 test to determine whether repeated exposure reduces silver uptake rate, andsuccessfully aged materials may then continue to Stage 2 testing. The materials under testinclude metallic and polymeric materials with various surface finishes, treatments, andcoatings, as well as select other materials historically used in spacecraft water systems. Thistest began in August 2019, and thus only includes early results; future follow-on papers willinclude additional results as the test progresses. The ultimate goal builds a broad, easilycomparable data set that can be used to guide material selections for silver biocide-compatible spacecraft water system design.
Silver Biocide↗
COMPATIBILITY OF MATERIALS WITH HIGH TEMPERATURE POTASSIUM.
Compatibility of materials with high temperature potassium
POTASSIUM↗
Assessing Compatibility of Natural Gas Pipeline Materials with Hydrogen, CO 2 , and Ammonia
Here, in this study, we examine the efficacy of repurposing natural gas (NG) pipelines for transporting hydrogen blends (with NG), ammonia, and CO 2 (gaseous and supercritical) from the standpoint of materials compatibility. Some information pertaining to component performance is also included, especially those components critical for pressurization and monitoring of flow. A listing of critical pipeline components and materials was developed, and their compatibilities was assessed for each fluid or gas type based on known compatibilities. Results indicate that pipeline materials should be suitable for gaseous CO 2 and anhydrous ammonia, but hydrogen blends greater than 12% may be problematic. Current compressor/regulator stations will not be suitable for use with either supercritical CO 2 or ammonia. Important knowledge gaps were identified, including (1) polymer performance with hydrogen/NG blends at low pressures, (2) compressor/regulator station polymers and epoxy coating materials with supercritical CO 2 , and (3) metal performances of hydrogen/NG blends at low pressures.
03 NATURAL GAS↗
Polymer Matrix Composite Material Oxygen Compatibility
Carbon fiber/polymer matrix composite materials look promising as a material to construct liquid oxygen (LOX) tanks. Based on mechanical impact tests the risk will be greater than aluminum, however, the risk can probably be managed to an acceptable level. Proper tank design and operation can minimize risk. A risk assessment (hazard analysis) will be used to determine the overall acceptability for using polymer matrix composite materials.
Owens, Tom↗
A survey of compatibility of materials with high pressure oxygen service
The available information on the compatibility of materials with oxygen as applied to the production, transport, and applications experience of high pressure liquid and gaseous oxygen is compiled. High pressure is defined as about 2000 to 3000 psia. Since high pressure projections sometimes can be made from lower pressure data, some low pressure data are also included. Low pressure data are included if they are considered helpful to a better understanding of the behavior at high pressures.
Hust, J. G.↗
Mishaps with Oxygen in NASA Operations
Data from a substantial number of oxygen mishaps obtained from NASA and contractor records are presented. Information from several Air Force records, concerning oxygen accidents involving aircraft operations, are also included. Descriptions of the mishaps and their causes, for both liquid and gaseous oxygen in ground test facilities and space vehicle systems, are given. A number of safety regulations aimed at reducing the accident probability is discussed. The problems related to material compatibility and materials testing are considered, and the limited information on factors affecting the ignition of materials in oxygen is presented. In addition, details are given of several of the accident/incidents listed in order to define the combination of conditions causing the mishap. In addition to propellant system mishaps, accident/incidents which occurred in space and ground system structures were included, as well as those in electrical systems, ground support facilities, ordnance, and related operations.
Ordin, Paul M.↗
Assessment of Silver Based Disinfection Technology for CEV and Future US Spacecraft
Silver biocide offers a potential advantage over iodine, the current state-of-the-art in US spacecraft disinfection technology, in that silver can be safely consumed by the crew. As such, silver may reduce the overall complexity and mass of future spacecraft potable water systems, particularly those used to support long duration missions. A primary technology gap identified for the use of silver biocide is one of material compatibility. Wetted materials of construction are required to be selected such that silver ion concentrations can be maintained at biocidally effective levels. Preliminary data on silver biocide depletion rates in heritage spacecraft potable water system wetted-materials of construction has been gathered as part of a multi-phase test project aimed at the characterization of silver based biocide technology through: development of preferred materials lists, investigation of silver biocide forms and delivery methods, down-selection of silver biocide technologies, and integrated testing. A 10% - 20% loss in silver ion concentration per day was observed for acid passivated Nitronic 40 tubing with surface area to volume (S/V) ratios of approximately 4.59 cm-1. The Nitronic 40 tubes were tested both with and without biocide pretreatment. Silver biocide depletion was also observed at approximately 0.1% per day for the first 35 days of exposure to acid passivated Inconel 718 coupon, S/V of approximately 0.14 cm-1. Surface analysis by scanning election microscopy (SEM) suggested deposition of silver metal on both test materials. SEM analysis also provided evidence of potential variability in the passivation process for tube configuration of the Nitronic 40 test apparatus. These preliminary results are presented and discussed herein, along with the current project status.
Callahan, Michael R.↗
Advanced techniques for determining long term compatibility of materials with propellants
The search for advanced measurement techniques for determining long term compatibility of materials with propellants was conducted in several parts. A comprehensive survey of the existing measurement and testing technology for determining material-propellant interactions was performed. Selections were made from those existing techniques which were determined could meet or be made to meet the requirements. Areas of refinement or changes were recommended for improvement of others. Investigations were also performed to determine the feasibility and advantages of developing and using new techniques to achieve significant improvements over existing ones. The most interesting demonstration was that of the new technique, the volatile metal chelate analysis. Rivaling the neutron activation analysis in terms of sensitivity and specificity, the volatile metal chelate technique was fully demonstrated.
Green, R. L.↗
UHT-CAMANCHE: Ultra-High Temperature Ceramic Additively Manufactured Compact Heat Exchangers
The conceptual basis for this project is the convergence of advanced ultra-high temperature ceramic materials and additive manufacturing technologies to produce compact ceramic heat exchangers with complex internal flow path geometries. Task areas were broadly divided into materials and manufacturing development, heat exchanger design, component testing, and techno-economic analysis. Technical challenges included the design and commissioning of new test facilities, improving feature resolution and deposition rate of ceramic additive manufacturing techniques, establishing process-structure-property relationships in additively manufactured ultra-high temperature ceramics, and assessing high temperature materials compatibility in CO 2 environments. The primary candidate material evaluated in this work is a composite comprising zirconium diboride (ZrB2) with 30 vol. % silicon carbide (SiC) which was selected based on its desirable combination of high temperature mechanical properties, high thermal and electrical conductivities, and oxidation resistance. High solids loaded ZrB2-SiC pastes suitable for extrusion-based additive manufacturing were developed for the first time as part of this work. Materials compatibility studies indicate this material oxidizes in CO 2 to form a protective borosilicate scale which transforms to pure silica above 1000°C. Parts made by additive manufacturing displayed enlarged grain sizes produced by pressureless sintering as compared to hot-press sintering. Increases in microstructural coarseness have outsized effect on oxidation performance up to 1400°C due to incomplete oxidation of coarse large diameter SiC particles resulting in lower amounts of silica that apparently inhibit protective scale formation. Additive manufacturing as a forming technique did not appear to significantly affect thermal conductivity, hardness, or elastic modulus, though flexural strength was reduced by half or more as compared to traditionally hot-pressed materials. This effect was attributed to the presence of strength-limiting flaws (ca. 40 microns in size) originating from extrudate inhomogeneities that could potentially be eliminated with further process improvements. Attempts to attain economies of scale for production of multi-kilowatt scale heat exchangers by ceramic additive manufacturing proved difficult. Lack of automation and a modest extrusion rate while retaining fine feature resolution made the overall process labor intensive and limited experimental throughput. A number of full-scale components were taken through post-process heat treatments including drying, binder burnout, and sintering; however, none survived without significant flaws or cracks. Therefore, no operational data from a newly installed heat exchanger test loop were able to be obtained during the performance period. Continued research and development is recommended to improve economic feasibility of ceramic additive manufacturing by standardizing the use of advanced sensors, artificial intelligence, and automation tools to reduce associated labor costs and accelerate production rates. The materials and manufacturing techniques demonstrated in this work are likely to find applications in defense and energy applications.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
Compatibility Studies of Hydrogen Peroxide and a New Hypergolic Fuel Blend
Several preliminary materials compatibility studies have been conducted to determine the practicality of a new hypergolic fuel system. Hypergolic fuel ignites spontaneously as the oxidizer decomposes and releases energy in the presence of the fuel. The bipropellant system tested consists of high-test hydrogen peroxide (HTP) and a liquid fuel blend consisting of a hydrocarbon fuel, an ignition enhancer and a transition metal catalyst. In order for further testing of the new fuel blend to take place, some basic materials compatibility and HTP decomposition studies must be accomplished. The thermal decomposition rate of HTP was tested using gas evolution and isothermal microcalorimetry (IMC). Materials were analyzed for compatibility with hydrogen peroxide including a study of the affect welding has on stainless steel elemental composition and its relation to HTP decomposition. Compatibility studies of valve materials in the fuel blend were performed to determine the corrosion resistance of the materials.
Baldridge, Jennifer↗
Lignin-based jet fuel and its blending effect with conventional jet fuel
Sustainable aviation fuels (SAFs) must demonstrate specific physical and chemical properties as well as material compatibility (i.e., seal swell) to be used as an aviation turbine fuel. Several alternative jet fuels incorporated in ASTM D7566 are comprised mainly of n/iso-alkanes and can only be blended up to 50 vol% due to material compatibility and density issues. Prior work illustrated the ability of cycloalkanes to replace aromatics’s role in material compatibility. Here, we report the first archival documentation of a feedstock and chemical process to yield a product composition able to complement existing SAF ASTM D7566 annexes. A lignin-based jet fuel (LJF) blend components is generated and composed of mostly C7-C18 mono, di, and tri-cycloalkanes. The neat LJF was blended with conventional jet fuel at 10 vol% (LJF blend) to simulate an ASTM “Fast Track” evaluation process. Fuel properties that are critical to engine operability (ATSM D4054 Tier 3 & 4) were either predicted or experimental tested based on the volume availability. All LJF blend’s critical properties fall within the experience range of conventional jet fuel, with o-ring swelling exceeding the typical range of conventional fuels. Here, these results in total support the potential use of this LJF pathway to complement other SAF pathways and achieve 100% drop-in SAF.
09 BIOMASS FUELS↗
A survey of compatibility of materials with high pressure oxygen service.
The literature on high pressure oxygen compatibility has been surveyed in order to present the existing state of knowledge. Searches have been conducted of NASA and NBS data retrieval systems. In addition, many individuals, active in the field, were contacted in order to retrieve useful unpublished information. Compatibility data, such as mechanical impact, pneumatic impact, ignition temperature, and flash-and-fire point, were compiled for pressures above 200 bar. Lower pressure data were included if they were useful for extrapolation to pressures above 200 bar. These data, too numerous to be given here, are available from the authors. Brief descriptions of the trends of these data are given. Recommendations for additional high pressure studies are included.
Hust, J. G.↗
Survey of materials for hydrazine propulsion systems in multicycle extended life applications
An assessment is presented of materials compatibility data for hydrazine monopropellant propulsion systems applicable to the Space Shuttle vehicle missions. Materials were evaluated for application over a 10-yr/100-mission operational lifetime with minimum refurbishment. A general materials compatibility rating for a broad range of materials and several propellants based primarily on static liquid propellant immersion testing and an in-depth evaluation of hydrazine decomposition as a function of purity, temperature, material, surface conditions, etc., are presented. The most promising polymeric material candidates for propellant diaphragms and seals appear to have little effect on increasing hydrazine decomposition rates, but the materials themselves do undergo changes in physical properties which can affect their 10-yr performance in multicycle applications. The available data on these physical properties of elastomeric materials as affected by exposure to hydrazine or related environments are presented.
Coulbert, C. D.↗
Enabling In-Core Strain Measurement: Printed Sensors for Advanced Reactors
Advances in nuclear energy systems require an improved understanding of fuels, cladding, and structural materials; however, the extreme environmental conditions at irradiation test facilities often limit mechanical property evaluation to post-irradiation examination. In-situ monitoring techniques can accelerate materials qualification by providing direct insight into real-time material behavior during irradiation testing. Additively manufactured (AM) strain gauges offer a compact, material-compatible alternative to commercial sensors, particularly where space constraints, attachment limitations, or material compatibility requirements complicate conventional sensor use. This poster presents an overview of the development and testing of AM strain gauges in nuclear-relevant environments, demonstrating their potential to enhance structural health monitoring capabilities during irradiation experiments.
36 - MATERIALS SCIENCE↗
Corrosion in Other Liquid Metals (Li, PbLi, Hg, Sn, Ga)
A wide range of liquid metals have been considered for application in nuclear fission and fusion reactors. Liquid mercury (Hg) was tested as a coolant and working fluid for nuclear fission reactors and as a neutron source target. Liquid lithium and lead lithium eutectic (Li and PbLi) have been extensively studied for fusion reactor designs including plasma facing components (PFCs). Liquid tin and gallium (Sn and Ga) have recently gained attention as alternative PFCs due to their low vapor pressure and chemical stability. To enable successful application of these less common liquid metals, corrosion compatibility with containment materials needs to be investigated. For this purpose, this article reviews corrosion behavior and structural material compatibility, including ferrous alloys, refractory metals, and ceramics, by liquid Li, PbLi, Sn, Ga, and Hg.
Jun, Jiheon↗
Measure the effect of molten halide salt exposure on creep rupture lifetime
Recent resurgence in the research and commercial interests in molten salt reactors (MSRs) as a viable advanced reactor concept to achieve the short- and long-term climate goals has resulted in ongoing efforts to demonstrate their commercial potential. These are relying on a combination of the extensive legacy knowledge from the molten salt reactor experiment (MSRE) and relatively recent data on materials compatibility of structural materials of interest such as 316H in molten salts environments. However, there is a critical lack of data on the mechanical behavior of alloys of interest for MSRS such as 316H, 617 and 709 in molten fluoride (FLiNaK or FLiBe) or chloride (NaCl-MgCl 2 ) salts. Limited legacy data from the molten salt reactor experiment (MSRE) program showed a significant reduction in creep rupture strength of a Ni-base alloy (Ni-15Cr-7Fe wt.%) in the molten fluoride NaF-ZrF4-UF4 (50-46-4 mol.%) salt. With ongoing efforts to commercialize different molten salt reactor concepts, the industry can considerably benefit from quantitative information on the impact of molten halide salts on the engineering properties such as creep and fatigue strength of materials of interest. Creep tests for 316H were conducted with fluoride (FLiNaK) and chloride (NaCl-MgCl 2 ) salts tat 650°C/150 MPa while alloys 709 and 617 were tested with FLiNaK at 700C/158 MPa and 750C.146 MPa respectively. Baseline tests were conducted in air to assess the impact of the molten salts on the creep behavior.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
Measure the effect of molten halide salt exposure on creep rupture lifetime
Recent resurgence in the research and commercial interests in molten salt reactors (MSRs) as a viable advanced reactor concept to achieve the short- and long-term climate goals has resulted in ongoing efforts to demonstrate their commercial potential. These are relying on a combination of the extensive legacy knowledge from the molten salt reactor experiment (MSRE) and relatively recent data on materials compatibility of structural materials of interest such as 316H in molten salts environments. However, there is a critical lack of data on the mechanical behavior of alloys of interest for MSRS such as 316H, 617 and 709 in molten fluoride (FLiNaK or FLiBe) or chloride (NaCl-MgCl 2 ) salts. Limited legacy data from the molten salt reactor experiment (MSRE) program showed a significant reduction in creep rupture strength of a Ni-base alloy (Ni-15Cr-7Fe wt.%) in the molten fluoride NaF-ZrF4-UF4 (50-46-4 mol.%) salt. With ongoing efforts to commercialize different molten salt reactor concepts, the industry can considerably benefit from quantitative information on the impact of molten halide salts on the engineering properties such as creep and fatigue strength of materials of interest. Creep tests for 316H were conducted with fluoride (FLiNaK) and chloride (NaCl-MgCl 2 ) salts tat 650°C/150 MPa while alloys 709 and 617 were tested with FLiNaK at 700C/158 MPa and 750C.146 MPa respectively. Baseline tests were conducted in air to assess the impact of the molten salts on the creep behavior.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗