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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 901 records · Page 50
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Modeling of High-Temperature Corrosion of Zirconium Alloys Using the eXtended Finite Element Method (X-FEM)

Oxidation modeling in modern nuclear fuel performance codes is currently limited by the lack of coupling with mechanics, thus preventing proper description of how high-temperature oxidation impacts mechanical properties. This is mostly due to the fact that the finite difference formalism adopted in corrosion models is incompatible with the direct coupling with mechanics in the finite element modeling employed in modern nuclear fuel performance codes. In this study, a physically based zirconium alloy corrosion model called the Coupled-Current Charge Compensation (C4) model, which was initially developed for operating temperature conditions, has been updated to include high-temperature corrosion in order to provide additional critical information (e.g., oxygen concentration profile) under loss-of-coolant accident (LOCA) conditions—information lacking in existing empirical models. The C4 model was implemented in the MOOSE finite-element framework developed at Idaho National Laboratory, enabling it to be used in the BISON nuclear fuel performance code based on the MOOSE framework. To precisely track the different interfaces at a relatively low computational cost, the eXtended Finite Element Method (X-FEM) was applied in MOOSE. The model’s results were compared to those of existing empirical models as well as metallographic analysis of high-temperature oxidized Zircaloy-4 coupons. Oxygen diffusivities in the a and ß phases resulting from this comparison closely agree with those found in the literature. The C4 model implemented with X-FEM in MOOSE now has the capability to accurately predict oxide, oxygen-stabilized a, and prior ß phase layer growth kinetics under isothermal exposure at high temperature (1000–1500°C). Furthermore, in contrast with the empirical models, the C4 model accounts for the finite thickness of the fuel cladding. It can predict the oxygen concentration profile evolution through the whole cladding, enabling evaluation of the remaining ductile thickness—a crucial variable for modeling the mechanical behavior of the fuel cladding under LOCA. Furthermore, this implementation allows direct coupling with mechanics, at a low computing cost, using finite-element-based nuclear fuel performance codes such as BISON.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Environmental degradation of electroplated nickel and copper coated SS316H in molten FLiNaK salt

Corrosion of nickel and copper electroplated coatings on SS316H in molten FLiNaK salt was studied. 500- and 1000-hour static corrosion tests were performed in molten FLiNaK at 700 degrees Celsius. Characterization of the coatings following corrosion indicated that they did not degrade in the molten salt during the corrosion experiment and fully protected the underlying SS316H from chromium dissolution. Interdiffusion between the copper coating and SS316H was extremely limited, interdiffusion between the nickel coating and SS316H. Diffusion modelling revealed that the nickel coatings still significantly reduced chromium dissolution over 60 years despite the interdiffusion.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Oxidation kinetics and microstructure evolution of high Mn stainless-steel alloy in CO 2 at 700 °C

Oxidation kinetics and scale formation were examined in 21–2N Stainless Steel alloys in a CO 2 environment at 700 °C. Several characterization techniques were used to identify the morphology, crystallographic structure, and chemical composition of the oxide scale formation during exposures up to 1925 h. High manganese content played an important role in homogenous oxide scale formation of Mn 3 O 4 and MnCr 2 O 4 at the scale/gas and scale/alloy interfaces and as an FCC stabilizer in the alloy. Depletion of Mn resulted in an FCC to BCC phase transformation at the scale/alloy interface. No carburization was observed, indicating that the oxide layer is preventing carbon uptake.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Combined chlorine dioxide–membrane distillation for the treatment of produced water

Membrane distillation (MD) is a promising technique for desalinating hypersaline brine, such as produced water (PW). To date, fouling and scaling have remained as major challenges for MD implementation. In this study, chlorine dioxide combined with induced air floatation (ClO 2 -IAF) was systematically investigated as a pretreatment prior to MD. First, the ClO 2 generation based on sodium chlorite and hydrochloric acid was optimized to maximize the on-demand ClO 2 production. The maximum production yield of 18.4% was obtained with 4wt.% NaClO 2 and 20wt.% HCl solutions, with a molar ratio of 1:1.25. Then, two real PW samples were pretreated, and removal efficiencies for total suspended solids (TSS), turbidity, iron, and total organic carbon (TOC) were comprehensively studied by varying the ClO 2 dosage between 6 and 91 mg/L. The ClO 2 -IAF pretreatment displayed TSS and turbidity removals above 90% and TOC removal close to 55%. Further, the PW constituents such as benzene, toluene, ethylbenzene, xylene (BTEX), and total petroleum hydrocarbons (TPH) were analyzed and quantified throughout the cascade of the treatments. The volatiles like BTEX were mainly removed by air floatation, while saturated hydrocarbons such as TPH were retained by the hydrophobic membrane. The MD long-term stability without any in-place cleaning was evaluated, and the membrane withstood for twenty two days without wetting, suggesting that optimizing oxidation pretreatment is critical for mitigating the fouling in MD. Results suggest that organic fouling in PW could be effectively reduced by the pretreatment, but further treatment is required to mitigate the scaling, which resulted in MD wetting.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

The impact of capillary heterogeneity on CO 2 flow and trapping across scales

Capillary heterogeneity has been identified over the last decade as a key control on subsurface CO 2 flow behavior during geological CO 2 sequestration. These heterogeneities can be formed in all sedimentary rocks, ranging from slight variations in the sand grain sizes to extensive sequences of interbedded sands, shales, and limestones. Capillary heterogeneity has been largely, although not entirely, overlooked in subsurface flow modeling because it is assumed to only directly influence fluid redistribution over scales of centimeters to meters. However, even small-scale fluid movements can result in dramatic impacts on the mobility and trapping of the CO 2 over kilometers. Therefore, neglecting capillary heterogeneity at multiple scales could potentially lead to errors in modeling and predicting field-scale plume migration. In this review paper, we aim to provide a consistent overview to (1) establish that capillary heterogeneity can have a major impact on CO 2 plume migration, (2) establish the respective length scales at which capillary heterogeneity matters, and (3) provide guidance for numerical modeling. This review covers pertinent literature and extracts key observations from the core to the field scales. Experimental studies have shown that millimeter-decimeter scale capillary heterogeneity can cause the so-called capillary heterogeneity trapping in addition to pore-scale residual trapping. Even at such a small scale, capillary heterogeneity can already lead to complex upscaled constitutive relationships, such as flow-rate dependent and anisotropic relative permeability, which affects field-scale CO 2 migration even when field-scale heterogeneities are present. Under gravity-dominated flow regimes, centimeter-meter scale capillary heterogeneity can entrap a significant amount of CO 2 at field scale, not just after imbibition but also during drainage. In certain cases, the presence of capillary heterogeneity can even completely stop the vertical movement of the CO 2 plume, hence greatly reducing leakage risks. At meter-kilometer scale, the influence of capillary heterogeneity is more pronounced and can hinder or redirect CO 2 migration in both lateral and vertical directions. The impact of capillary heterogeneity across multiple spatial scales poses a great challenge in modeling CO 2 migration at field scale, because it is practically impossible to build a field-scale earth model with grid blocks at millimeter scale. We recommend a hierarchical modeling approach to address this challenge. At field scale, earth models are built to capture geological features and heterogeneities in high but still practical grid resolutions. For each facies or rock type of the field-scale model, high- resolution meter-scale “conceptual” models are built with millimeter-scale grid blocks to capture representative fine-scale bedding geometries and heterogeneities in various environments of deposition, bridging the gap from subcore scale to the size of a field-scale simulation grid block. Upscaling is then used to preserve the smaller-scale flow dynamics of various rock types in field-scale simulations. Here, future work is needed to (1) refine, improve, and validate the hierarchical modeling approach; (2) build libraries of fine-scale bedding models for facies in various environments of deposition; (3) quantify multiscale capillary heterogeneity effects under subsurface uncertainties; (4) gain learning from different storage formations; and (5) establish best practices that balance accuracy and computational speed.

Capillary heterogeneity↗
DOE OSTI2021

A screening model for predicting injection well pressure buildup and plume extent in CO 2 geologic storage projects

We present a new screening model for predicting injection well pressure buildup and CO 2 plume migration for CO 2 geologic sequestration projects. The model requires only limited information and is quite accurate when compared to detailed simulation results. Such models can assist project developers during the early days of project planning (e.g., for 45Q related projects), and also help regulators perform simple checks against detailed numerical models. The screening model consists of two correlations: one for injectivity index in terms of the slope of the CO 2 fractional flow curve, and the second for total storage efficiency within the footprint of plume as a function of gravity number and slope of the CO 2 fractional flow curve. Using these two correlations, as well as a knowledge of some basic reservoir characteristics and estimates of fluid properties from standard correlations, the injection-well pressure buildup and CO 2 plume extent in the formation can be readily estimated. Finally, the new correlations show a good match with the results of the underlying simulations, and also provide good agreement with independent calculations for two example problems.

42 ENGINEERING↗
DOE OSTI2026

Basin-scale analysis of Mokelumne River Formation for multi-well CO 2 injection

Large-scale carbon sequestration will likely require multiple projects injecting CO 2 into the same subsurface formation, raising concerns about safe operation and efficient use of storage capacity. This study evaluates the long-term response of the Mokelumne River Formation in California’s Sacramento Basin to multi-megaton CO 2 injection using three geologic models of the formation and the open-source simulator GEOS. The analysis focuses on three aspects of reservoir performance: (1) average pressure increase and dissolved CO 2 mass after 30 years for varying well counts and injection rates, (2) pressure interference in a multi-well configuration, and (3) dynamic storage capacity with identification of overpressure-prone regions. The results show that average formation pressure increases linearly with injected mass, while CO 2 dissolution exhibits mixed scaling: approximately linear with the number of wells but sublinear with injection rate, indicating that distributing injection across more wells enhances dissolution more effectively than increasing per-well rates. Pressure-interference effects are significant, with lower-permeability conditions delaying their onset but amplifying their magnitude at later times. Dynamic capacity, defined by the first occurrence of pressure exceeding the local overburden-based limit anywhere in the formation, varies across geologic models and assumed overburden pressure gradients. A lower fidelity geologic model predicts nearly twice the storage capacity of the two higher fidelity models, which consistently estimate approximately 1 Gt under the upper-bound overburden pressure gradient considered for the Sacramento Basin. In all model scenarios, overpressure develops away from injection wells, particularly in higher-elevation regions, highlighting the importance of basin-scale modelling for identifying risks beyond the immediate well vicinity.

Basin-scale↗
DOE OSTI2024

High resolution identification and quantification of diffuse deep groundwater discharge in mountain rivers using continuous boat-mounted helium measurements

Discharge of deeply sourced groundwater to streams is difficult to locate and quantify, particularly where both discrete and diffuse discharge points exist, but diffuse discharge is one of the primary controls on solute budgets in mountainous watersheds. The noble gas helium is a unique identifier of deep groundwater discharge because groundwater with long residence times is commonly enriched in helium. In this study, a portable mass spectrometer was used to measure longitudinal variation in dissolved helium concentrations in two mountainous rivers at high spatial resolution not feasible with traditional sampling techniques. Helium profiles were then simulated using a mass-balance model to quantify longitudinal variation in groundwater discharge to the receiving rivers. Results indicate helium concentrations were enriched by multiple orders of magnitude above atmospheric equilibrium in both rivers and that this persisted for up to 18 km below observed pulse inputs in the Colorado River. Helium mass-balance models match observed longitudinal patterns with the exception of sharp initial increases in helium observed in the rivers. Increased longitudinal groundwater discharge rates correspond to mapped geologic structures in both watersheds that likely transport deep geothermal water. Models show variable sensitivity to spatial assignment of input variables representing the groundwater source, illustrating the importance of collecting data from discrete groundwater discharges where possible. The methodology shows promise for field experiments designed to assess air–water exchange rates and to quantify total groundwater discharge from a combination of discrete and diffuse sources.

Deep groundwater↗
DOE OSTI2023

Hydrogen production with seawater-resilient bipolar membrane electrolyzers

Generation of H 2 and O 2 from untreated water sources represents a promising alternative to ultrapure water required in contemporary proton exchange membrane-based electrolysis. Bipolar membrane-based devices, often used in electrodialysis and CO 2 electrolysis, facilitate impure water electrolysis via the simultaneous mediation of ion transport and enforcement of advantageous microenvironments. Herein, we report their application in direct seawater electrolysis; we show that upon introduction of ionic species such as Na + and Cl - from seawater, bipolar membrane electrolyzers limit the oxidation of Cl - to corrosive OCl - at the anode to a Faradaic efficiency (FE) of 0.005%, while proton exchange membrane electrolyzers under comparable operating conditions exhibit up to 10% FE to Cl oxidation. In conclusion, the effective mitigation of Cl - oxidation by bipolar membrane electrolyzers underpins their ability to enable longer-term seawater electrolysis than proton exchange membrane assemblies by a factor of 140, suggesting a path to durable seawater electrolysis.

08 HYDROGEN↗
DOE OSTI2026

The forward physics facility: Physics opportunities and conceptual design

The Forward Physics Facility (FPF) is a proposed extension of the HL-LHC program designed to exploit the unique scientific opportunities offered by the intense flux of high energy neutrinos, and possibly new particles, in the far-forward direction. Located in a well-shielded cavern 627 m downstream of one of the LHC interaction points, the facility will support a broad and ambitious physics program that significantly expands the discovery potential of the HL-LHC. Equipped with four complementary detectors -- FLArE, FASER$ν$2, FASER2, and FORMOSA -- the FPF will enable breakthrough measurements that will advance our understanding of neutrino physics, quantum chromodynamics, and astroparticle physics, and will search for dark matter and other new particles. With this Letter of Intent, we propose the construction of the FPF cavern and the construction, integration, and installation of its experiments. We summarize the physics case, the facility design, the layout and components of the detectors, as well as the envisioned collaboration structure, cost estimate, and implementation timeline.

Astroparticle physics↗
DOE OSTI2022

Processes and mechanisms of coastal woody-plant mortality

Observations of woody plant mortality in coastal ecosystems are globally widespread, but the overarching processes and underlying mechanisms are poorly understood. This knowledge deficiency, combined with rapidly changing water levels, storm surges, atmospheric CO 2 , and vapor pressure deficit, creates large predictive uncertainty regarding how coastal ecosystems will respond to global change. Here we synthesize the literature on the mechanisms that underlie coastal woody-plant mortality, with the goal of producing a testable hypothesis framework. The key emergent mechanisms underlying mortality include hypoxic, osmotic, and ionic-driven reductions in whole-plant hydraulic conductance and photosynthesis that ultimately drive the coupled processes of hydraulic failure and carbon starvation. The relative importance of these processes in driving mortality, their order of progression, and their degree of coupling depends on the characteristics of the anomalous water exposure, on topographic effects, and on taxa-specific variation in traits and trait acclimation. Greater inundation exposure could accelerate mortality globally; however, the interaction of changing inundation exposure with elevated CO 2 , drought, and rising vapor pressure deficit could influence mortality likelihood. Models of coastal forests that incorporate the frequency and duration of inundation, the role of climatic drivers, and the processes of hydraulic failure and carbon starvation can yield improved estimates of inundation-induced woody-plant mortality.

salinity↗
DOE OSTI2022

Phylogenetic analyses and reclassification of the oleaginous marine species Nannochloris sp. “desiccata" (Trebouxiophyceae, Chlorophyta), formerly Chlorella desiccata , supported by a high-quality genome assembly

Microalgae are diverse, with many gaps remaining in phylogenetic and physiological understanding. Thus, studying new microalgae species increases our broader comprehension of biological diversity, and evaluation of new candidates as algal production platforms can lead to improved productivity under a variety of cultivation conditions. Chlorella is a genus of fast-growing species often isolated from freshwater habitats and cultivated as a source of nutritional supplements. However, the use of freshwater increases competition with other freshwater needs. We identified Chlorella desiccata to be worthy of further investigation as a potential algae production strain, due to its isolation from a marine environment and its promising growth and biochemical composition properties. Long-read genomic sequencing was conducted for C. desiccata UTEX 2526, resulting in a high-quality, near chromosome level, diploid genome with an assembly length of 21.55 Mbp in only 18 contigs. We also report complete circular mitochondrial and chloroplast genomes. Phylogenomic and phylogenetic analyses using nuclear, chloroplast, 18S rRNA, and actin sequences revealed that this species clades within strains currently identified as Nannochloris (Trebouxiophyceae, Chlorophyta), leading to its reclassification as Nannochloris sp. “desiccata” UTEX 2526. The mode of cell division for this species is autosporulation, differing from the type species N. bacillaris. As has occurred across multiple microalgae genera, there are repeated examples of Nannochloris species reclassification in the literature. This high-quality genome assembly and phylogenetic analysis of the potential algal production strain Nannochloris sp. “desiccata” UTEX 2526 provides an important reference and useful tool for further studying this region of the phylogenetic tree.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2021

Identification and selection of optimal reference genes for qPCR-based gene expression analysis in Fucus distichus under various abiotic stresses

Quantitative gene expression analysis is an important tool in the scientist’s belt. The identification of evenly expressed reference genes is necessary for accurate quantitative gene expression analysis, whether by traditional RT-PCR (reverse-transcription polymerase chain reaction) or by qRT-PCR (quantitative real-time PCR; qPCR). In the Stramenopiles (the major line of eukaryotes that includes brown algae) there is a noted lack of known reference genes for such studies, largely due to the absence of available molecular tools. Here we present a set of nine reference genes (Elongation Factor 1 alpha (EF1A), Elongation Factor 2 alpha (EF2A), Elongation Factor 1 beta (EF1B), 14-3-3 Protein, Ubiquitin Conjugating Enzyme (UBCE2), Glyceraldehyde-3-phosphate Dehydrogenase (GAPDH), Actin Related Protein Complex (ARP2/3), Ribosomal Protein (40s; S23), and Actin) for the brown alga Fucus distichus . These reference genes were tested on adult sporophytes across six abiotic stress conditions (desiccation, light and temperature modification, hormone addition, pollutant exposure, nutrient addition, and wounding). Suitability of these genes as reference genes was quantitatively evaluated across conditions using standard methods and the majority of the tested genes were evaluated favorably. However, we show that normalization genes should be chosen on a condition-by-condition basis. We provide a recommendation that at least two reference genes be used per experiment, a list of recommended pairs for the conditions tested here, and a procedure for identifying a suitable set for an experimenter’s unique design. With the recent expansion of interest in brown algal biology and accompanied molecular tools development, the variety of experimental conditions tested here makes this study a valuable resource for future work in basic biology and understanding stress responses in the brown algal lineage.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2024

Surface water geochemistry along St. Louis River Estuary (Duluth/Superior, MN/WI)

This dataset is aimed at understanding changes in surface water chemistry associated with urbanization in the Great Lakes region. Surface water chemistry including cations, anions, organic and inorganic carbon, and nitrogen were collected from six locations along St. Louis River – a freshwater estuary entering Lake Superior (Duluth/Superior, MN/WI). The Duluth/Superior, MN/WI metropolitan area is the largest port on the United States side of Lake Superior. Samples were collected near different land uses every two weeks from late July 2023 to the onset of ice cover in November 2023. Water samples were analyzed using In-Situ AquaTroll 500 Multiparameter Sonde with Ammonium Ion Selective Electrode and Chlorophyll-a sensor (unfiltered), METTLER TOLEDO FiveEasy Plus FP20 and METTLER TOLEDO LE407 probe (unfiltered); HACH DR300 Pocket Colorimeter Iron FerroVer (filtered 0.22 μm in field); Shimadzu TOC-L Total Organic Carbon Analyzer with TNM-L Total Nitrogen Unit (filtered 0.22 μm in field); Agilent 8900 triple quadrupole ICP-MS (ICP-QQQ) (filtered 0.22 μm in field); and Dionex ICS-6000 HPIC System (filtered 0.22 μm in field).The data package is comprised of 5 files. dd.csv contains the description of columns in Geochemistry_LSNERR_water.csv and Sampling_sites.csv. flmd.csv contains descriptions of each file in the dataset. README.txt contains description of the dataset structure and file content. Geochemistry_LSNERR_water.csv contains geochemistry data for six sampling locations along the St. Louis River. Sampling_sites.csv contains latitude and longitude coordinates for each of the six sampling site locations along the St. Louis River.This data has not been previously published.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

Carbon Storage Open Database

The Carbon Storage Open Database is a collection of spatial data obtained from publicly available sources published by several NATCARB Partnerships and other organizations. The carbon storage open database was collected from open-source data on ArcREST servers and websites in 2018, 2019, 2021, and 2022. The original database was published on the former GeoCube, which is now EDX Spatial, in July 2020, and has since been updated with additional data resources from the Energy Data eXchange (EDX) and external public data resources. The shapefile geodatabase is available in total, and has also been split up into multiple databases based on the maps produced for EDX spatial. These are topical map categories that describe the type of data, and sometimes the region for which the data relates. The data is separated in case there is only a specific area or data type that is of interest for download. In addition to the geodatabases, this submission contains: 1. A ReadMe file describing the processing steps completed to collect and curate the data. 2. A data catalog of all feature layers within the database. Additional published resources are available that describe the work done to produce the geodatabase: Morkner, P., Bauer, J., Creason, C., Sabbatino, M., Wingo, P., Greenburg, R., Walker, S., Yeates, D., Rose, K. 2022. Distilling Data to Drive Carbon Storage Insights. Computers & Geosciences. https://doi.org/10.1016/j.cageo.2021.104945 Morkner, P., Bauer, J., Shay, J., Sabbatino, M., and Rose, K. An Updated Carbon Storage Open Database - Geospatial Data Aggregation to Support Scaling -Up Carbon Capture and Storage. United States: N. p., 2022. Web. https://www.osti.gov/biblio/1890730 Morkner, P., Rose, K., Bauer, J., Rowan, C., Barkhurst, A., Baker, D.V., Sabbatino, M., Bean, A., Creason, C.G., Wingo, P., and Greenburg, R. Tools for Data Collection, Curation, and Discovery to Support Carbon Sequestration Insights. United States: N. p., 2020. Web. https://www.osti.gov/biblio/1777195 Disclaimer: This project was funded by the United States Department of Energy, National Energy Technology Laboratory, in part, through a site support contract. Neither the United States Government nor any agency thereof, nor any of their employees, nor the support contractor, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof.

carbon storage↗
DOE OSTI2024

Prospective Seal Name Catalog for U.S. Sedimentary Basins V1.0

The Prospective Seal Name Catalog for U.S. Sedimentary Basins V1.0 is an aggregation of prospective seal units for prospective storage resources within the USA for geologic carbon storage in both onshore and offshore basins. The catalog is intended to guide users to available literature and data resources. Prospective seal names are displayed with respect to the associated prospective storage resource target, for which the specified prospective seal may act as a confining layer for CO2 storage. A prospective seal unit’s lithology, position with respect to the reservoir (Primary, Secondary, Intraformational, etc.), and age (Geologic Period) are included when stated in the original literature or data resource. The information source for each record in the catalog includes the published citation, year of publication, resource type (Journal Article, Event Proceedings, etc.) and additional record notes.

Basin↗
DOE OSTI2024

Prospective Seal Unit Spatial Extent Database for U.S. Sedimentary Basins

The Prospective Seal Unit Spatial Extent Database for U.S. Sedimentary Basins contains a series of spatial datasets representing spatial extents of publicly available data for caprock and seal rock units within the Appalachian Basin, Denver-Julesburg Basin, Great Valley Basin (Sacramento and San Joaquin Basins), Illinois Basin, Michigan Basin, San Juan Basin, U.S. Gulf Coast Basin, and Williston Basin. The database is designed to support carbon storage feasibility and resources assessment for carbon transport and storage (CTS) projects while displaying the spatial extent of prospective seal units and provide a guide to the original data source. This database leverages publicly available data resources from authoritative sources (e.g. U.S. Geological Survey, State Geologic Surveys, and published reports), and aims to help guide users to understand the seal unit's spatial coverage and data gaps from the regional to sub-basin/field scale. The database is organized by seal unit/formation, including the spatial extent for data found to be available for the seal unit. The various datasets represented include spatial extents of the lithologic formation, depth to top structural contour maps, and thickness/isopach maps. Included in this submission are the following resources: 1. Geodatabase/Dataset: “prospective-seal-unit-extents-2025.gdb” 2. ReadMe: “readme-prospective-seal-unit-spatial-extent-dataset-2025.pdf” 3. Data Catalog: “prospective-seal-unit-spatial-extents-data-catalog-2025.xlsx” 4. Data Sources Key: “data-source.csv” Please see NETL disclaimers here: https://netl.doe.gov/home/disclaimer

Basin↗
DOE OSTI2023

Development of Corrosion Resistant Coatings for Structural Materials for Liquid Fueled Molten Salts Reactors Applications (Final Report)

Current structural alloys, code certified for the MSRs temperature ranges, contain high levels of chromium, making them highly susceptible to molten halide salt corrosion. One potential solution to circumvent the need for code certification of novel alloys, which is expensive and time consuming, is to design claddings that will protect the underlying code certified materials from corrosion damage during operation. In this work, we examined the corrosion of Ni and Cu electroplated, Ni and CuNi weld overlay, Mo-laser clad, and carburized claddings on SS316H for use in molten salt reactor environments. After characterization of the cladded materials (Task 1), static corrosion tests were used to assess corrosion resistance of the claddings in typical molten fluoride salts (Task 2). The corrosion tests were performed in molten FLiNaK at 700°C up to 1000 hours. Pre- and post-corrosion Scanning Electron Microscopy (SEM), energy-dispersive-spectroscopy (EDS), Transmission Electron Microscopy (TEM), X-ray Diffraction (XRD) and glow-discharge-optical-emission-spectroscopy (GDOES) were performed on cladding cross-sections and surfaces to evaluate degradation. The Cu and Ni electroplated samples, as well as the carburized samples, showed excellent corrosion resistance relative to the bare SS316H. To assess high temperature cladding stability, ageing experiments were performed at temperatures up to 900 C in inert atmosphere for the electroplated and carburized samples and a diffusion model was developed to predict long term cladding behavior (Task 3). It was found that the Cu cladding was basically insensitive to the high temperature ageing, except for small secondary phases forming at the interface. On the other hand, the Ni electroplated cladding experienced significant interdiffusion. Nevertheless, the gain in corrosion resistance for a 100μm Ni electroplated cladding is phenomenal, with more than 50% reduction in chromium dissolution from the substrate material for the first 15 years of salt exposure at 700°C. To assess radiation resistance and phase stability, high-temperature 4MeV Ni heavy ion irradiation was performed across the cladding/substrate interface up to 50 displacement-per-atom (DPA) at 500°C and 700°C to assess the phase stability and irradiation behaviors of the electroplated systems (Task 4). The Ni and Cu electroplated systems did not experience void swelling at the contrary to the SS316H substrate due to their nanocrystalline nature. Some level of recrystallization was observed in the cladding, as well as radiation induced segregation and enhanced diffusion. The interface acted as a potent sink for point defects with the presence of a void denuded zone. The mechanical properties of the claddings were assessed using thermal shock, micro-indentation, nano-indentation, and four-point bend testing experiments (Task 5). These experiments were performed on the claddings in as-received, corroded, irradiated, and thermally aged states to determine the effects of typical molten salt reactor environments on cladding integrity. No significant mass loss was observed after repeated thermal shocks. While the electroplated samples softened after high-temperature ageing, irradiation hardening compensate this effect, such that there is little different with the as-received materials. The results of these experiments suggest that the electroplated (copper/nickel) show the greatest promise for application in molten salt reactor development. These claddings prevented any chromium dissolution from occurring during the static corrosion experiments. Additionally, they demonstrated favorable properties for high temperature diffusion, phase stability, interfacial mechanical properties, and irradiation resistance. Weld-overlay cladding are also of great interest and could reach properties similar to the electroplated samples upon optimization (especially with multiple weld passes). The carburized SS316H showed excellent behavior as well, but more work needs to be done to assess their long-term stability. Finally, the Mo-laser clad system was not pursued further due to the manufacturing challenges. It is also worth noting that the Ni cladding systems should behave relatively well in terms of weldability since the Ni-weld overlay microstructure and associated corrosion rate are sound. While the NiCu weld-overlay has even lower corrosion rates than the Ni-weld overlay, more studies on welding of Cu-electroplated systems are necessary since Cu clusters are known to embrittle steels.

36 MATERIALS SCIENCE↗