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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 973 records · Page 54
All sourcesNASA NTRSDOE OSTI
DOE OSTI2015

Annual Report FY2014 Alternative Fuels DISI Engine Research

Due to concerns about future petroleum supply and accelerating climate change, increased engine efficiency and alternative fuels are of interest. This project contributes to the science-base needed by industry to develop highly efficient DISI engines that also beneficially exploit the different properties of alternative fuels. Lean operation is studied since it can provide higher efficiencies than traditional non-dilute stoichiometric operation. Since lean operation can lead to issues with ignition stability, slow flame propagation and low combustion efficiency, focus is on techniques that can overcome these challenges. Specifically, fuel stratification can be used to ensure ignition and completeness of combustion, but may lead to soot and NO x emissions challenges. Advanced ignition system and intake air preheating both promote ignition stability. Controlled end-gas autoignition can be used maintain high combustion efficiency for ultra-lean well-mixed conditions. However, the response of both combustion and exhaust emission to these techniques depends on the fuel properties. Therefore, to achieve optimal fuel-economy gains, the combustion-control strategies of the engine must adopt to the fuel being utilized.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2018

Issue Update to LWR SiC/SiC Cladding Handbook of Properties

This report aims to provide properties data of silicon carbide (SiC) fiber–reinforced SiC matrix (SiC/SiC) composites for use in modeling for their application as accident-tolerant fuel cladding for light water reactors (LWRs). The properties data presented are specifically for geometries relevant to fuel cladding tubes, although many properties can be derived or predicted based on data from planar geometry specimen data. This report presents various properties, including mechanical properties, thermal properties, chemical stability under normal and off-normal operation conditions, hermeticity, and irradiation resistance. Table S.1 provides a high level summary of those properties mainly for nuclear-grade SiC/SiC composites fabricated via a chemical vapor infiltration (CVI) route, which has been updated from the previous report (ORNL/TM - 2017/385). The newly added data include statistical tensile properties, hydrothermal corrosion behavior of environmental barrier coating on SiC, and accurate temperature- and dose-dependent swelling of SiC/SiC composites.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2018

Radiological Considerations of Top-off Operation at NSLS-II

High current (500 mA) and low emittance (~1 nm) have been specified for NSLS-II to achieve ultra high brightness in a medium energy (3 GeV) storage ring (1) . This leads to the expectation that the lifetime in NSLS-II will be limited by Touschek scattering, and after commissioning will settle in at ~3 hours. It may well be less in the early days of operation. At the same time, the intensity stability specified by the user community is 1% or better.

36 MATERIALS SCIENCE↗
DOE OSTI2021

The DPG Method for the Convection-Reaction Problem Revisited

We study both conforming and non-conforming versions of the practical DPG method for the convection-reaction problem. We determine that the most common approach for DPG stability analysis (construction of a local Fortin operator) is infeasible for the convection-reaction problem. We then develop a line of argument based on the direct construction of a global Fortin operator; we find that employing a polynomial enrichment for the test space does not suffice for this purpose, motivating the introduction of a (two-element) subgrid mesh. The argument combines mathematical analysis with numerical experiments

42 ENGINEERING↗
DOE OSTI2021

Exploring Whether Subsurface Fluid Production Can Minimize Triggered Seismicity in Geothermal Fields

Fluid injection and production related to energy recovery and other industrial operations alter the pressure and stress state of subsurface reservoirs which can lead to induced seismicity. Here, the primary goal is to investigate the hypothesis that the modulation of stress state in subsurface reservoirs through fluid injection/production operations can reduce the likelihood of inducing seismicity. Validation of this mitigation strategy will provide an active operational method to control induced seismicity in subsurface reservoir exploitations such as geothermal energy recovery and carbon storage. In this project, we analyze the relationship between extensive fluid production and the paucity of aftershock activity at the Coso Geothermal plant (CGP) following the 2019 Ridgecrest earthquake sequence, where high rates of aftershock triggering were expected. We developed a high-fidelity multiphase coupled thermo-hydro-mechanical (THM) model to simulate fluid injection/production activities at the CGP between 1986 and 2020. THM results of surface subsidence due to high rates of fluid production agree well with field observations from global positioning system (GPS) and interferometric synthetic aperture radar (InSAR). Subsequently, the variations of pore pressure, temperature and stress state were used to drive numerical earthquake simulations of the aftershock response to the 2019 Ridgecrest earthquakes. The earthquake simulations show that seismic quiescence may occur following the Ridgecrest event, depending on the initial stress state at the time of the mainshock and at the initiation of geothermal energy production. Seismic quiescence occurs in 20% of the cases we explored, where rates are decreased by 50% of the background rate in the two years following the mainshock. In circumstances where aftershock rates increase near the CGP following Ridgecrest, the average rate change is a factor of two larger than background rates from simulations with no operations. These findings indicate that unlike many other operations that bring faults closer to failure, operations at the CGP are acting to stabilize faults such that triggering in the current stress state is minimal.

58 GEOSCIENCES↗
DOE OSTI2022

A Novel Catalytic Membrane Reactor for DME Synthesis from Renewable Resources

Production of liquid fuels or chemicals from CO 2 (captured from the air or flue gases) and renewable hydrogen presents a new approach to producing clean fuels domestically. While significant progress has been made in the area of renewable electricity generation from solar and wind, a large gap remains with respect to the production of renewable liquid fuels/chemicals. Other processes for producing liquid fuels/chemicals from renewable electricity are constrained by thermodynamic limitations, making them prohibitively expensive and impractical. The team is overcoming these limitations and developing catalytic membrane reactor processes with high yields and low energy penalties. Supported by the Advanced Research Projects Agency-Energy (ARPA-E) of the US Department of Energy (DOE), GTI Energy and partners have been developing a technology for the production of renewable dimethyl ether (DME) from carbon dioxide (CO 2 ) and renewable hydrogen (H 2 ) using a novel catalytic membrane reactor and demonstration of this system at a scale of 1 kg/day. DME is a clean-burning, non-toxic fuel with a high cetane value (55-60), making it an excellent diesel alternative. DME can be stored as a liquid under moderate pressure, eliminating the need for the high-pressure containers used for CNG or cryogenics, as in the case of LNG. DME is also approved as a renewable fuel under the U.S. Environmental Protection Agency’s Renewable Fuels Standard (RFS), making it eligible for Renewable Identification Numbers (RINs) credits. By producing DME through the catalytic conversion of captured CO 2 and renewable H 2 , this process will produce renewable liquid transportation fuel and a means of large-scale utilization of captured CO 2 . In the DME synthesis process, CO 2 and H 2 are fed to a hollow fiber catalytic membrane reactor at 300-600 psig that contains a bi-functional catalyst that combines two reactions, methanol synthesis (CO 2 + 3H 2 → CH 3 OH + H 2 O) and methanol dehydration (2CH 3 OH → CH 3 OCH 3 + H 2 O), into a one-step process to produce DME. The bifunctional catalyst converts methanol to DME, enabling higher overall CO 2 conversion. A Cu/ZnO/ZrO 2 /Al 2 O 3 (CZZA) catalyst is used for methanol synthesis and is coupled with a zeolite catalyst H-ZSM-5 for dehydration. This one-step process intensifies a process that would otherwise require multiple reaction steps. However, combining these two reactions results in increased water production which inhibits catalytic activity. Here, the Na + -gated, water-transport membrane (Science, vol. 367, pp. 667, 2020), removes water in situ, shifting the thermodynamic equilibrium towards product formation while decreasing kinetic inhibition from water adsorption onto the catalyst surface. The Na + gated, water-transport nanochannel membrane showed H 2 O/CO 2 selectivity of 560 at 250 °C and 300 psig for H 2 O/CO 2 /CO/H 2 /MeOH gas mixtures. The selectivities of H 2 O/H 2 , H 2 O/CO, and H 2 O/MeOH were 190, 170, and 80, respectively. In a laboratory-scale membrane reactor, DME synthesis testing using this membrane, a DME production rate of 440 g DME /kg cat /h was achieved at 260 °C and 550 psig. Compared to the packed bed reactor, the CO 2 conversion and DME production rate in the membrane reactor were 80% and three times higher, respectively. A prototype test system (1 kg/day) was designed, constructed, and tested. A DME production rate of 1.31 kg/day and a DME productivity of 360 g/h/kg were achieved in the prototype membrane reactor. Good stability was demonstrated during 150-h continuous operation and multiple startups/shutdowns tests.

10 SYNTHETIC FUELS↗
DOE OSTI2024

Ergodicity, lack thereof, and the performance of reservoir computing with memristive networks and nanowire

Networks composed of nanoscale memristive components, such as nanowire and nanoparticle networks, have recently received considerable attention because of their potential use as neuromorphic devices. In this study, we explore ergodicity in memristive networks, showing that the performance on machine leaning tasks improves when these networks are tuned to operate at the edge between two global stability points. We find this lack of ergodicity is associated with the emergence of memory in the system. We measure the level of ergodicity using the Thirumalai-Mountain metric, and we show that in the absence of ergodicity, two different memristive network systems show improved performance when utilized as reservoir computers (RC). We highlight that it is also important to let the system synchronize to the input signal in order for the performance of the RC to exhibit improvements over the baseline.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2022

Machine Learning Solutions for a Stable Grid Recovery

Grid operating security studies are typically employed to establish operating boundaries, ensuring secure and stable operation for a range of operation under NERC guidelines. However, if these boundaries are severely violated, existing system security margins will be largely unknown, as would be a secure incremental dispatch path to higher security margins while continuing to serve load. As an alternative to the use of complex optimizations over dynamic conditions, this work employs the use of machine learning to identify a sequence of secure state transitions which place the grid in a higher degree of operating security with greater static and dynamic stability margins. Several reinforcement learning solution methods were developed using deep learning neural networks, including Deep Q-learning, Mu-Zero, and the continuous algorithms Proximal Reinforcement Learning, and Advantage Actor Critic Learning. The work is demonstrated on a power grid with three control dimensions but can be scaled in size and dimensionality, which is the subject of ongoing research.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2025

Assessing Seismic Risk for CO2 Geologic Storage: Comparative Analysis of the Delaware Basin and Basin and Range Province Projects

ABSTRACT: Effective management of induced seismicity is critical for safe and sustainable CO2 storage. This study evaluates fault slippage risks in the Delaware Basin (Texas) and Basin and Range Province (Utah), integrating geological, operational, and geomechanical parameters to assess fault stability and seismic hazard mitigation. In the Delaware Basin, two sites were analyzed under an injection rate of 20,000 bbl/day over 25 years. One site showed low fault slip risk, while the other exhibited higher reactivation potential due to proximity to critically stressed faults. Sensitivity analysis revealed that increased pore pressure significantly heightened slip potential, highlighting the necessity of precise pressure control and real-time monitoring. In the Basin and Range Province, fault stability was evaluated at Neck of the Desert, Escalante Desert, Parowan, and Beaver sites under injection rates of 8,750 bbl/day per site over 30 years. Minimal fault slip risk was observed at Neck of the Desert and Escalante Desert sites, whereas Parowan and Beaver sites exhibited elevated slip potential due to semi-critically stressed faults sensitive to modest pore pressure increases. The findings demonstrate that fault slippage analysis, combined with sensitivity analysis of pore pressure and friction coefficients, is essential for understanding seismic risks. Continuous monitoring, adaptive injection management, and rigorous geomechanical analysis are key strategies for minimizing induced seismicity in CO2 sequestration projects.

58 GEOSCIENCES↗
DOE OSTI2026

Summary of GFL Inverter Capability and Performance: Malawi [Slides]

This presentation provides a comprehensive comparison of inverter-based resource (IBR) technical requirements across multiple international grid codes - including IEEE 2800, ESO, EirGrid, and Malawi's evolving regulatory framework - to support capacity building for electricity-sector institutions in Malawi. It highlights key performance expectations for grid-following (GFL) inverters across critical domains such as primary and fast frequency response, ramping behavior, frequency and voltage ride-through capabilities, reactive power and voltage control, ROCOF withstand, phase jump tolerance, system strength considerations, protection schemes, and dynamic modeling requirements. Emphasizing a "Do no harm, do something, do more" philosophy, the document synthesizes best practices and operational benchmarks to guide the integration and stability of inverter-based resources within Malawi's power system. The presentation forms part of the SABESS Center of Excellence initiative supported by the Global Energy Alliance for People and the Planet.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2019

Formed-in-place Ceramic Systems for Sealing and Flow Control in Geothermal Applications

Conventional oil and gas tools are frequently unsuitable for downhole applications in geothermal wells, largely due to uncased well configurations and their extreme thermal/chemical fluid conditions. Consequently, relatively common O&G tools like bridge plugs and sand control screens are difficult or at times impossible to implement in geothermal wells. In commercial oil and gas, thermite-based tools are being developed for intervention and decommissioning applications, and gaining field experience and credibility. We are developing and testing such systems for geothermal applications, with the objective of forming ceramic sealing and flow control features in-situ. The process uses self-propagating thermite reactions, in which a metal is combined with an oxidizer to release significant amounts of energy in a controlled, non-explosive manner. These solid phase reactions can be engineered to generate ceramic products with specific physical and flow characteristics. We are developing and testing formulations and wireline deployment tools which yield low to high permeability as needed, and preferentially expand to fill boreholes in both large diameter and slimhole wells. Near term applications are bridge plugs for P&A operations, screens for sand control and borehole stabilization, and lost circulation control during drilling. Laboratory tests have demonstrated the ability to form these products under high temperature and pressure conditions. Field tests are in planning to demonstrate the full-scale performance of these tools. This paper will present the status and results of this demonstration project, in its first year of advanced development for the DOE geothermal technologies program. New developments utilizing thermite tools in the HP/HT oil and gas domain will also be highlighted, particularly those which may have utility in geothermal applications.

02 PETROLEUM↗
DOE OSTI2012

Comparisons on thin and thick neutron target for low energy proton beam

As the progress on accelerator physics and neutronics, the compact neutron sources driven by low energy and high intensity beam are becoming extensively developed and researched all around the world. The neutron target of an accelerator driven neutron source is one of the key components, and the stability of the neutron target affect the operation and performance of the neutron facility. When a low energy proton is projected to the beryllium target, the main reaction is the inelastic scattering between the proton and extra-nuclear electrons. As the decreasing of proton energy, the rate of elastic scattering between proton and target nucleus begins to increase. When the energy of proton is very low, the pickup charge reaction begins to appear. Focus on the problems brought by high intensity proton beam such as proton implantation, radiation damages, heat deposition and gas production, we performed sufficient numerical simulations for both thin and thick target determined by proton range. The results show that the critical problem for thick target is the proton implantation, causing the forming of bubbles and beryllium flaked in vacuum. The thin target sacrifices a little neutron yield, but avoid the proton stopped in target, and decrease the radiation damage and energy deposition. (authors)

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

Frozen Freedom: Unleashing Grocery Store Demand Flexibility: Preprint

Grocery stores consumed approximately 3% of total electricity used by commercial buildings in the U.S. in 2018 (EIA 2018), representing a unique end-use load profile characterized by the critical use of refrigerated display cases. Exploring demand response (DR) scenarios in grocery stores presents an opportunity to enhance the efficiency and sustainability of surrounding communities. In addition, recent studies demonstrate that implementing control algorithms considering demand flexibility strategies can lead to load and peak reductions in standalone refrigerated display cases. Because small business grocery stores operate on thin margins, the energy bill cost savings DR might provide could make a positive difference toward continued operations. Still, uncertainty remains about the extent of demand flexibility potential controls could provide when coupling refrigeration with whole building operation. To enhance economic viability and grid stability, it is essential to quantify the load flexibility capability of grocery stores. Advanced controls can optimize energy consumption by responding to load shedding, shifting, and DR events, as well as daily Time-of-Use (TOU) rates without compromising food safety. Using both quantitative data and interviews with community-based organizations, we developed a full-size store model and two small store models with controlled refrigerated cases, HVAC, and lighting systems based on actual grocery store properties. Through simulations, we have assessed load flexibility strategies with varied DR events. The results highlight potential for energy and peak reduction with advanced or basic controls. However, interviews and data indicate that more support is needed to make DR strategies consistently accessible to small grocery stores.

demand flexibility↗
DOE OSTI2021

Effect of thermal aging and irradiation on microstructure and crack growth response of Alloy 690

Nickel-base Alloy 690 and the associated weld Alloys 52 and 152 are typically used for nozzle penetrations in replacement heads for pressurized water reactor (PWR) vessels, because of their excellent overall resistance to general corrosion and environmental degradation, primarily stress corrosion cracking (SCC). However, many of the existing PWRs reactors are expected to operate for 40-80 years. Likewise, advanced water-cooled small modular reactors (SMRs) will use Ni-Cr alloys and are expected to receive initial operating licenses for 60 years. Hence, the thermal stability of Ni-Cr alloys is a potential concern for the long-term performance of both existing and advanced nuclear plants, and possibly spent fuel storage containers. The objective of this research is to understand the microstructural changes occurring in high-Cr, Ni-based Alloy 690 during long time exposure to the reactor operating temperatures, and the effect of these changes on the service performance. One area of particular concern is the potential for long range ordering (LRO), i.e. formation of the intermetallic Ni 2 Cr phase under prolonged exposure to reactor temperatures and/or irradiation, which can increase strength, decrease ductility, and cause dimensional changes or lead to in-service embrittlement of components made with these alloys. Hence, this research focused on the microstructural evolution and the SCC response of Alloy 690 under accelerated thermal aging and irradiation conditions. The materials studied involved Alloy 690 from two sources: (i) Alloy 690 plate from an Alloy 152 dissimilar metal weld (DMW) joining the Alloy 690 plate to Alloy 533 LAS, aged at three different temperatures (370°C, 400°C and 450°C) for up to 75,000h (equivalent to 60 years of service), and (ii) specimens neutron-irradiated in the BOR-60 reactor up to 40 dpa. For aged Alloy 690 specimens, hardness was found to increase with aging time, however, the microstructural characterization by means of synchrotron X-ray did not find evidence of LRO. The microstructural characterization of neutron-irradiated specimens by TEM found no evidence of LRO either. Testing in a primary water environment of Alloy 690 specimens aged to a 60-year service equivalent revealed a fatigue and corrosion fatigue crack growth responses similar to those measured on the un-aged alloy. The SCC CGR response was also low. Overall, the two Alloy 690 heats investigated in this work, aged up to 60-year service equivalents or exposed to neutron irradiation up to 40 dpa, did not exhibit a deterioration in microstructure or performance.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Effect of Thermal Aging on Microstructure and Stress Corrosion Cracking Behavior of an Alloy 152 1st Layer Butter Weldment

Nickel-based Alloy 690 and the associated weld Alloys 52 and 152 are typically used for nozzle penetrations in replacement heads for pressurized water reactor (PWR) vessels, because of their excellent overall resistance to general corrosion and environmental degradation, primarily stress corrosion cracking (SCC). However, many of the existing PWRs are expected to operate for 40- 80 years. Likewise, water-cooled small modular reactors (SMRs) will use Ni-Cr alloys and are expected to receive initial operating licenses for 60 years. Hence, the thermal stability of Ni-Cr alloys is critical for the long-term performance of both existing and advanced nuclear power plants, and possibly spent fuel storage containers. The objective of this research is to understand the microstructural changes occurring in high-Cr, Ni-based Alloy 152 weldments during long time exposure to the reactor operating temperatures, and the effect of these changes on the service performance. One area of particular concern is the potential for long range ordering (LRO), i.e. formation of the intermetallic Ni2Cr phase under prolonged exposure to reactor temperatures and/or irradiation, which can increase strength, decrease ductility, and cause dimensional changes or lead to in-service embrittlement of components made with these alloys. Hence, this research focused on the microstructural evolution and the SCC response of Alloy 152 under accelerated thermal aging. The materials studied involved three heats of Alloy 152 used to produce a dissimilar metal weld (DMW) joining an Alloy 690 plate to an Alloy 533 low alloy steel (LAS) plate, thermally aged at three different temperatures (370°C, 400°C and 450°C) for different durations up to 75,000h (equivalent to 60 years of reactor service). The microstructural characterization by means of synchrotron X-ray conducted in small, 0.2 mm - step line scans in the high-deformation regions of the weld root – covering areas spanning from the weld heat affected zone (HAZ) in Alloy 690 to the weld and weld butter on LAS - did not show evidence of LRO in any of the three Alloy 152 heats aged at 370°C and 450°C to an equivalent of 60 years of service. However, the first weld butter layer has high levels of deformation and is highly susceptible to SCC even in its non-aged condition. Nanohardness testing confirmed the extreme hardening with aging (ΔHV ≅ 100) at two locations within this weldment. In absence of LRO, hardening is suspected to be due to thermally-induced Cr carbide precipitation and coarsening. Testing in a primary water environment of the 1st layer of Alloy 152 weld butter aged at 370°C to a 60-year service equivalent revealed a fatigue and corrosion fatigue crack growth responses similar to those measured on the un-aged alloys. Similarly, the SCC CGR response of the aged weld butter does not appear to show a deterioration in performance, however, the difficult-to-test weldment geometry may affect the test results.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2016

The lightest organic radical cation for charge storage in redox flow batteries

In advanced electrical grids of the future, electrochemically rechargeable fluids of high energy density will capture the power generated from intermittent sources like solar and wind. To meet this outstanding technological demand there is a need to understand the fundamental limits and interplay of electrochemical potential, stability, and solubility in low-weight redox-active molecules. By generating a combinatorial set of 1,4-dimethoxybenzene derivatives with different arrangements of substituents, we discovered a mini-malistic structure that combines exceptional long-term stability in its oxidized form and a record-breaking intrinsic capacity of 161 mAh/g. The nonaqueous redox flow battery has been demonstrated that uses this molecule as a catholyte material and operated stably for 100 charge/discharge cycles. Furthermore, the observed stability trends are rationalized by mechanistic considerations of the reaction pathways.

25 ENERGY STORAGE↗
DOE OSTI2022

Effect of thermal aging on microstructure and crack growth response of Alloy 152 weld

Nickel-based Alloy 690 and the associated weld Alloys 52 and 152 are typically used for nozzle penetrations in replacement heads for pressurized water reactor (PWR) vessels, because of their excellent overall resistance to general corrosion and environmental degradation, primarily stress corrosion cracking (SCC). However, many of the existing PWRs are expected to operate for 40-80 years. Likewise, advanced water-cooled small modular reactors (SMRs) will use Ni-Cr alloys and are expected to receive initial operating licenses for 60 years. Hence, the thermal stability of Ni-Cr alloys is a potential concern for the long-term performance of both existing and advanced nuclear power plants, and possibly spent fuel storage containers. The objective of this research is to understand the microstructural changes occurring in high-Cr, Ni-based Alloy 152 weldments during long time exposure to the reactor operating temperatures, and the effect of these changes on the service performance. One area of particular concern is the potential for long range ordering (LRO), i.e. formation of the intermetallic Ni2Cr phase under prolonged exposure to reactor temperatures and/or irradiation, which can increase strength, decrease ductility, and cause dimensional changes or lead to in-service embrittlement of components made with these alloys. Hence, this research focused on the microstructural evolution and the SCC response of Alloy 152 under accelerated thermal aging. The materials studied involved three heats of Alloy 152 used to produce a dissimilar metal weld (DMW) joining an Alloy 690 plate to an Alloy 533 low alloy steel (LAS) plate, thermally aged at three different temperatures (370°C, 400°C and 450°C) for up to 75,000h (equivalent to 60 years of service). The microstructural characterization by means of synchrotron X-ray did not find evidence of LRO in any of the three heats aged to an equivalent of 60 years of service. Testing in a primary water environment of a heat of Alloy 152 aged at 370°C to a 60-year service equivalent revealed a fatigue and corrosion fatigue crack growth responses similar to those measured on the un-aged alloy. However, the SCC CGR response of the aged sample appears to show a deterioration in performance.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2023

Effect of thermal aging on microstructure and stress corrosion cracking behavior of Alloy 152 weldment

Nickel-based Alloy 690 and the associated weld Alloys 52 and 152 are typically used for nozzle penetrations in replacement heads for pressurized water reactor (PWR) vessels, because of their excellent overall resistance to general corrosion and environmental degradation, primarily stress corrosion cracking (SCC). However, many of the existing PWRs are expected to operate for 40-80 years. Likewise, water-cooled small modular reactors (SMRs) will use Ni-Cr alloys and are expected to receive initial operating licenses for 60 years. Hence, the thermal stability of Ni-Cr alloys is a potential concern for the long-term performance of both existing and advanced nuclear power plants, and possibly spent fuel storage containers. The objective of this research is to understand the microstructural changes occurring in high-Cr, Ni-based Alloy 152 weldments during long time exposure to the reactor operating temperatures, and the effect of these changes on the service performance. One area of particular concern is the potential for long range ordering (LRO), i.e. formation of the intermetallic Ni2Cr phase under prolonged exposure to reactor temperatures and/or irradiation, which can increase strength, decrease ductility, and cause dimensional changes or lead to in-service embrittlement of components made with these alloys. Hence, this research focused on the microstructural evolution and the SCC response of Alloy 152 under accelerated thermal aging. The materials studied involved three heats of Alloy 152 used to produce a dissimilar metal weld (DMW) joining an Alloy 690 plate to an Alloy 533 low alloy steel (LAS) plate, thermally aged at three different temperatures (370°C, 400°C and 450°C) for up to 75,000h (equivalent to 60 years of service). The microstructural characterization by means of synchrotron X-ray conducted in small, 0.2 mm - step line scans in the high-deformation regions of the weld root – covering areas spanning from the weld heat affected zone (HAZ) in Alloy 690 to the weld and weld butter on LAS - did not show evidence of LRO in any of the three Alloy 152 heats aged to an equivalent of 60 years of service. Testing in a primary water environment of two heats of Alloy 152 aged at 370°C to a 60-year service equivalent revealed a fatigue and corrosion fatigue crack growth responses similar to those measured on the un-aged alloys. However, the SCC CGR response of the aged samples appears to show a deterioration in performance, confirming our previous observation.

36 MATERIALS SCIENCE↗