Results for “ceramic processing” — Page 58

DOE OSTI2026

Siloxane-modified polycarbosilane flexible Prepregs for fabrication of ceramic matrix composites via compression molding and PIP densification

For this work, the development of ceramic matrix composites (CMCs) using 5 harness satin carbon fiber fabric impregnated with commercial polycarbosilane precursor plasticized by siloxane copolymer was investigated aiming to improve wetting behavior and shape conformability. The polycarbosilane precursor and polysiloxane plasticizer were mixed at varying weight ratios to obtain flexible preceramic resin prepreg cloths. 13 plies of preceramic polymer prepreg cloths were stacked in 0/90° layup and cured by compression molding, followed by densified via PIP process. The CMCs were densified with eight PIP cycles followed by final crystallization at 1600 °C. The CMCs made with 10 wt% polysiloxane loading showed lower viscosity of the prepreg resin as well as higher strength and displacement to failure compared to those fabricated from unplasticized polycarbosilane prepolymer. In contrast, at higher concentration of plasticizer, viscosity of the prepreg resin increased, and the CMC became more brittle; however, it exhibited considerably higher thermal conductivity.

Carbosilane↗

DOE OSTI2019

Doping Effect of Fe Ions on the Structural, Electrical, and Magnetic Properties of SrTiO{sub 3} Nanoceramic Matrix

In the present investigation, strontium titanate nanoceramic was synthesized by incorporating iron (Fe) ion with general formula SrTi{sub 1−x}Fe{sub x}O{sub 3} (x = 0.0, 0.1, 0.2, and 0.4) using sol-gel autocombustion method. The effect of Fe ions on the structural, morphological, electrical, dielectric, and magnetic properties of the prepared matrix has been investigated by various characterization techniques with the appropriate formulation. The structural properties such as phase space, crystallite size (D), and lattice parameter (a) of prepared matrix are calculated by X-ray diffraction (XRD) technique. The functional groups were analyzed by Fourier transform infrared spectroscopy (FT-IR). The surface morphology of the prepared nanoceramic matrix has been determined by using field emission scanning electron microscopy (FE-SEM) analysis. Calculation of average particle size and diffraction patterns was confirmed by using images from transmission electron microscopy (TEM) and selected area electron diffraction pattern (SAED), respectively. An energy dispersive spectrum analysis (EDS) confirmed the compositional stoichiometry in the investigated matrix. Electrical conductivity increased the prepared sample due to the increasing in the Fe concentration and temperature. The dielectric parameters in the frequency range of 30 Hz to 1 MHz were found higher at lower frequencies. The pure SrTiO{sub 3} matrix shows a paramagnetic nature at room temperature, but for a higher concentration of Fe doping was used to observe the weak ferromagnetic nature. Therefore, due to Fe ion concentration, the properties of the prepared matrix have been completely varied and enhancement in the magnetic properties was observed.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

DOE OSTI2021

Synthesis of nanograined zirconium diboride microsphere powder feedstock via emulsification of suspensions

Ceramic nanograined materials have desirable characteristics compared to their macroparticle counterparts but are rarely used in industrial applications due to issues with poor handleability and health hazards. Due to interparticle forces that become more dominant as the particle size decreases, it is difficult to use nanomaterials to fill dies, spread on surfaces, or flow through hoppers found in various manufacturing processes. In this work, we report a scalable gelcasting solution and unique emulsification process to create microspheres composed of nanoscale powders to enhance the flowability and handleability of nanomaterials. The gelcasting solution and emulsification process can be used with any nanoparticle composition that can be suspended in a liquid phase. This paper reports the effects of various parameters on zirconium diboride microsphere formation, such as surfactant content and mixing conditions. The microspheres maintain the nano-scale characteristics of the powder but improve its flowability by using cross-linked polyvinyl alcohol to combine irregularly shaped zirconium diboride nanoparticles with a particle diameter of 60 nm into larger spherical particles with a d 50 ~25 μm. This hierarchical feedstock engineering design combine the positive characteristics of materials across both length scales and improve the flowability of the feedstock from a Hausner Ratio of 1.56 to 1.19. The materials produced using this technique can be used in thermal plasma spray, die filling for hot pressing or spark plasma sintering, and binder jet printing applications.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Polymeric and ceramic silicon-based coatings – a review

Silicon-based polymers are outstanding materials for coating applications. These compounds have excellent properties, such as strong adhesion to most substrates, and high chemical, thermal and UV resistance. Additionally, they can be converted into ceramic materials (polymer-derived ceramics) by a heat treatment and, in some cases, by chemical reactions or radiation. Hence, ceramic coatings can be obtained after deposition of the polymers by simple lacquer techniques. The properties and composition of polymeric and ceramic coatings can be changed by tailoring the chemical structure of the precursors or by the addition of fillers. This enables the preparation of coatings with a great variety of properties for different applications. In this review paper, the main aspects of the use of silicon polymers for coatings are elucidated. The advantages and disadvantages of these materials, and the processing methods developed are discussed. Lastly, a summary of the applications and the prospects for future research are presented.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Effect of alloying BaTiO 3 with BiZn 1/2 Ti 1/2 O 3 on polarization reversal

Changes in the polarization state of ferroelectric materials are mediated through the motion of planar defects such as domain walls. The interplay between the two processes that enable the inversion of the macroscopic polarization in ferroelectric materials, non-180° (domain reorientation) and 180° (domain reversal), is not well understood. In this work, time-resolved x-ray diffraction was carried out during the application of an external electric field to investigate the dynamic electric-field response mechanisms of BaTiO 3 (BT) and BiZn 1/2 Ti 1/2 O 3 (BZT)-modified BT (0.94BT-0.06BZT). These data evidence that the incorporation of BZT into BT fundamentally alters what processes are activated to reorient the polarization by 180°. Polarization reversal in BT is achieved through direct inversion of spontaneous dipoles. However, the addition of BZT into BT promotes a two-step polarization reversal process (i.e., two consecutive non-180° reorientation events).

36 MATERIALS SCIENCE↗

DOE OSTI2018

First‐principles study in an inter‐granular glassy film model of silicon nitride

Abstract Based on a previously constructed intergranular glassy film ( IGF ) model for bulk silicon nitride, a large periodic model of 3864 atoms containing 2 grains of different orientations from the main bulk β‐Si 3 N 4 and 2 IGF s was fully relaxed using the ab initio density‐functional theory package VASP . The relaxed structure was then used to calculate the electronic structure, density of states, interatomic bonding, partial charge distribution, and electron localization using the OLCAO method. Analysis of the data focuses on the interfacial regions between bulk β‐Si 3 N 4 and the Si‐O‐N glass layer with different orientations. The total bond order density ( TBOD ) is evaluated in different interfacial and bulk regions. We show minor differences in the internal cohesion between crystalline grains of different facets. However, the overall charges in the bulk crystal grains and in the glassy regions are electropositive which are balanced by the negatively charged interfacial region between the two. The presence of a less rigid glassy layer is the reason for structural flexibility in ceramics without a huge penalty in the steric energy. The optimization of the interfacial structure and bonding via the creation of defective sites is the atomic origin for the existence of the IGF in silicon nitride. The insights obtained from this detailed quantum mechanical analysis of a realistic IGF model are discussed including implications on the strength, fracture toughness, and processing methods. We also discuss the potential applications of our method to other complex materials systems.

Ching, Wai‐Yim↗

DOE OSTI2015

Report on status of execution of SiC step document

Advanced fuel claddings made entirely or mainly of silicon carbide (SiC) ceramics and/or composites are considered very attractive elements of the accident-tolerant fuels for the light water reactors. In order to translate the promise of SiC composite materials into a reliable fuel cladding, a coordinated program of component level design and materials development must be carried out with many key feasibility issues addressed a-priori to inform the process. With the primary objective of developing a draft blueprint of a technical program that addresses the critical feasibility issues; assesses design and performance issues related with manufacturing, operating, and off-normal events; and advances the technological readiness levels in essential technology elements, a draft plan for the Systematic Technology Evaluation Program for SiC/SiC Composite Accident-Tolerant LWR Fuel Cladding and Core Structures was developed in the FY-14 Advanced Fuels Campaign of the U.S. Department of Energy’s Fuel Cycles Research and Development Program. This document summarizes the status of execution of the technical plan within the activities at the Oak Ridge National Laboratory.

36 MATERIALS SCIENCE↗

DOE OSTI2018

High-Temperature Sapphire Pressure Sensors for Harsh Environments

The project aimed to develop and characterize an optical pressure sensor capable of withstanding high temperatures, up to 1000 °C. Survivability in harsh environments was enabled using sapphire for both the substrate and the optical fibers, therefore mitigating thermal expansion mismatch. Such material cannot be machined through conventional microfabrication techniques, and unique additive and subtractive methods had to be studied and implemented. Subtractive methods included laser-machining the sapphire substrate using a picosecond laser machining tool. At first, the parameters of importance were theoretically and experimentally evaluated such that the fluence, the pulse spacing, and the number of passes were found to strongly influence the laser ablation process. A simulation tool was designed to predict the final pattern when inputting a set of parameters and a profile. This model was complemented with laser ablation material physics models and Bayesian uncertainty analysis for one dimensional and three dimensional ablation processes. An additive process called thermocompression bonding was studied in order to seal the diaphragm substrate to the back cavity. At first, bonding strength using this technique was examined using the chevron-notch method that allow to determine the fracture toughness of this bond. This parameter is independent of the geometry used and therefore can be extended to other geometries used in actual sensor bonding. A theoretical and experimental study of internal damage caused by the laser micromachining of the sapphire material was carried out. The research identified enhanced strength and fracture toughness along laser ablated surfaces. This was determined using bend bar specimens and Vicker’s microindentations. Softening of the plasticity behavior (as indicated by nanoindentation experiments) was also investigated using finite deformation plasticity modeling via a contact mechanics finite element simulation. Good correlations between experiments and the model were achieved to determine material parameters that can be used in future MEMS based sensor design and modeling to minimize sensor failure loads. The enhanced strength and fracture toughness was determined to be due to compressive residual stress near laser ablated surfaces. This was confirmed through x-ray spectra taken along different crystal structure planes in combination and Bayesian uncertainty analysis. The Bayesian analysis inferred the entire residual strain tensor (six components) and the residual stress tensor. The results illustrated compressive in-plane stress was the most likely cause of enhanced strength and toughness after laser machining. Due to major equipment failures, a parallel route for fabricating the sensor was taken, using commercially available sapphire removal method (subtractive) and ceramic adhesive bonding (additive). The fully-packaged sensor utilized laser micromachining for the sapphire substrate fabrication and was comprised only of high-temperature-compatible materials. Calibration tests of the sensor in both room-temperature and high-temperature plane-wave tubes showed good linearity and consistent frequency response, in the tested frequency range. The sensor also showed good thermal stability in tests up to 300 °C, proving the fiber-optic lever and its packaging process to be a promising approach for high-temperature measurements. The calibration from 23 °C to 300 °C gave a raw sensitivity of 3.9 × 10 -7 V/Pa and a normalized sensitivity of 9.8 × 10 -8 Pa -1 which were consistent within the temperature range. The sensor had a resonance at 16.3 kHz and a flat band (±3 dB) up to 10.3 kHz. The noise floor of the sensor at 1 kHz was 316 nV/Hz 1/2 , resulting in a MDP of 0.8 Pa. Previously, diaphragm delamination due to CTE mismatch was found at 500 °C, causing packaging failure. Unfortunately high temperature validation in hot jet environment could not be made in time. In the future, it is suggested that the two sapphire substrates be bonded by thermal compression bonding with an intermediate platinum layer instead of using an alumina-based adhesive, and therefore achieve higher temperature capacity up to 1000 °C.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

DOE OSTI2021

Layer-structured triple-conducting electrocatalyst for water-splitting in protonic ceramic electrolysis cells: Conductivities vs. activity

Electron, proton and oxygen-triple-conducting materials are becoming the dominant steam electrode candidate to break the rate limit on the water-splitting reaction that throttles the performance of protonic ceramic electrolysis cells (PCECs). In this study, based on Pr 2 NiO 4+δ Ruddlesden-Popper phase, we manipulate these conductivities by Pr-site Ba substitution to probe the correlation of each conductivity with the kinetics of the elementary reaction steps. It is found that the proton conductivity is vital to sustain an extended active surface area for faster adsorption of reactants and desorption of products. The effect of oxygen conductivity is surprisingly found insignificant in the water-splitting reaction. On the contrary, surface oxygen removal is discovered as the most rate-limiting process. The electronic conductivity is not a direct limiting factor. However, an electron transfer process between the current collector and the electrode junction could introduce extra resistance that is perceptible at a high operating temperature range. The best water-splitting activity is obtained on a proton conductivity/oxygen surface desorption capability well-balanced sample after Ba substitution. As a result, a water-splitting reaction resistance of 0.022 Ωcm 2 , a current density of 1.96 A/cm 2 at 700 °C is achieved on Pr 1.7 Ba 0.3 NiO 4+δ , one of the best performances for PCECs.

25 ENERGY STORAGE↗

DOE OSTI2019

Tailoring the Properties of Calcium Aluminate Macro-Defect-Free Cements: From Brittle to Ductile Behavior

Cementitious macro-defect-free (MDF) materials can be obtained processing a mixture of a water-soluble polymer, namely polyvinyl alcohol (PVA) and the calcium aluminate cement. Based on process techniques typical of plastics, the MDF products can be obtained in complex forms and, thanks to the reduced water to cement ratio, w/c, their strength is very high compared to standard cements. However, these materials show both the sensitivity typical of water-soluble polymers, presenting a low glass transition temperature (T{sub g}), and the brittle behavior typical of ceramic materials and therefore low toughness. The aim of this work is to modify the mechanical properties of MDF cements by tuning their unacceptable brittle behavior. Water solution of carboxylate styrene butadiene rubber is used as reactive additives, and different mixture formulations are tested changing the rubber-like content both with respect to the fixed water content and PVA amounts. It is shown that the modifications of the organic phase imply small or negligible effects on paste formation of different recipes as detected by the torque–time responses. From flexural and fracture toughness tests, a wide range of responses was observed, and depending on the particular recipe, the mechanical behavior can be tuned from a brittle to a ductile behavior.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Technical Program Plan for INL Advanced Reactor Technologies Advanced Gas Reactor Fuel Development and Qualification Program

High-temperature gas cooled reactors (HTGRs) are graphite moderated nuclear reactors cooled with helium. Their high outlet temperatures and thermal energy conversion efficiency enable efficient and cost effective integration with non electricity generating applications. These applications include process heat and hydrogen production for petrochemical and other industrial processes that require operating temperatures between 300 and 900°C. HTGRs will supplement the use of premium fossil fuels such as oil and natural gas, improve overall energy security in the United States by reducing dependence on foreign fuels, and reduce carbon dioxide (CO2)/greenhouse gas emissions. The HTGR design uses helium as a coolant, graphite as a neutron moderator, and ceramic particle fuel. Helium is chemically inert and neutronically transparent. The graphite core slows down the neutrons, retains its strength at high temperatures, provides structural stability, and acts as a substantial heat sink during transient conditions. The ceramic particle fuel is extremely robust and retains the radioactive by products of the fission reaction within the coated particle under normal and off normal conditions.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2020

Technical Program Plan for INL Advanced Reactor Technologies Advanced Gas Reactor Fuel Development and Qualification Program

High-temperature gas cooled reactors (HTGRs) are graphite moderated nuclear reactors cooled with helium. Their high outlet temperatures and thermal energy conversion efficiency enable efficient and cost effective integration with non electricity generating applications. These applications include process heat and hydrogen production for petrochemical and other industrial processes that require operating temperatures between 300 and 900°C. HTGRs will supplement the use of premium fossil fuels such as oil and natural gas, improve overall energy security in the United States by reducing dependence on foreign fuels, and reduce carbon dioxide (CO2)/greenhouse gas emissions. The HTGR design uses helium as a coolant, graphite as a neutron moderator, and ceramic particle fuel. Helium is chemically inert and neutronically transparent. The graphite core slows down the neutrons, retains its strength at high temperatures, provides structural stability, and acts as a substantial heat sink during transient conditions. The ceramic particle fuel is extremely robust and retains the radioactive by products of the fission reaction within the coated particle under normal and off normal conditions.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2019

Technical Program Plan for INL Advanced Reactor Technologies Advanced Gas Reactor Fuel Development and Qualification Program

High-temperature gas cooled reactors (HTGRs) are graphite moderated nuclear reactors cooled with helium. Their high outlet temperatures and thermal energy conversion efficiency enable efficient and cost effective integration with non electricity generating applications. These applications include process heat and hydrogen production for petrochemical and other industrial processes that require operating temperatures between 300 and 900°C. HTGRs will supplement the use of premium fossil fuels such as oil and natural gas, improve overall energy security in the United States by reducing dependence on foreign fuels, and reduce carbon dioxide (CO2)/greenhouse gas emissions. The HTGR design uses helium as a coolant, graphite as a neutron moderator, and ceramic particle fuel. Helium is chemically inert and neutronically transparent. The graphite core slows down the neutrons, retains its strength at high temperatures, provides structural stability, and acts as a substantial heat sink during transient conditions. The ceramic particle fuel is extremely robust and retains the radioactive by products of the fission reaction within the coated particle under normal and off normal conditions.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Technical Program Plan for INL Advanced Reactor Technologies Advanced Gas Reactor Fuel Development and Qualification Program

High-temperature gas cooled reactors (HTGRs) are graphite moderated nuclear reactors cooled with helium. Their high outlet temperatures and thermal energy conversion efficiency enable efficient and cost effective integration with non electricity generating applications. These applications include process heat and hydrogen production for petrochemical and other industrial processes that require operating temperatures between 300 and 900°C. HTGRs will supplement the use of premium fossil fuels such as oil and natural gas, improve overall energy security in the United States by reducing dependence on foreign fuels, and reduce carbon dioxide (CO2)/greenhouse gas emissions. The HTGR design uses helium as a coolant, graphite as a neutron moderator, and ceramic particle fuel. Helium is chemically inert and neutronically transparent. The graphite core slows down the neutrons, retains its strength at high temperatures, provides structural stability, and acts as a substantial heat sink during transient conditions. The ceramic particle fuel is extremely robust and retains the radioactive by products of the fission reaction within the coated particle under normal and off normal conditions.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

Technical Program Plan for INL Advanced Reactor Technologies Advanced Gas Reactor Fuel Development and Qualification Program

High-temperature gas cooled reactors (HTGRs) are graphite moderated nuclear reactors cooled with helium. Their high outlet temperatures and thermal energy conversion efficiency enable efficient and cost effective integration with non electricity generating applications. These applications include process heat and hydrogen production for petrochemical and other industrial processes that require operating temperatures between 300 and 900°C. HTGRs will supplement the use of premium fossil fuels such as oil and natural gas, improve overall energy security in the United States by reducing dependence on foreign fuels, and reduce carbon dioxide (CO2)/greenhouse gas emissions. The HTGR design uses helium as a coolant, graphite as a neutron moderator, and ceramic particle fuel. Helium is chemically inert and neutronically transparent. The graphite core slows down the neutrons, retains its strength at high temperatures, provides structural stability, and acts as a substantial heat sink during transient conditions. The ceramic particle fuel is extremely robust and retains the radioactive by products of the fission reaction within the coated particle under normal and off normal conditions.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

Protonic Ceramics for Energy Storage & Electricity Generation with Ammonia (Final Report)

The commercial product resulting from this R&D project will enable cost-effective synthesis of the Carbon Neutral Liquid Fuel (CNLF) ammonia, a common chemical, at a small scale for energy and industrial applications using only intermittent renewable energy, water, and air as feedstocks. These products are also capable of producing electrical energy from the CNLF in a fuel cell mode of operation. Thus, the eventual commercial product enables both single direction production of either CLNF or electricity, or alternatively functions as a fully reversible, self-contained energy storage device. The renewed interest in developing electrolysis systems is driven, in part, by the burgeoning renewable, solar, and wind industries and the need for an energy conversion and storage technology that can convert intermittent solar and wind energy into the production of hydrogen. Electrolysis systems integrated into both distributed and central renewable power plants would utilize solar and wind energy as their primary power source to produce renewably generated hydrogen for local energy storage or chemical feedstock purposes. Ammonia is an excellent surrogate for hydrogen transportation. NH3 presents an attractive alternative to hydrogen as a working fluid in reversible devices towards a sustainable green energy-oriented future. Ammonia can be easily liquefied at room temperature at about 8 bar or at -33°C at ambient pressure. In contrast, the liquefaction temperature of hydrogen is -253°C at ambient pressure. NH3 has a significantly higher volumetric energy density (12.7 MJ/L) than compressed hydrogen (4.5 MJ/L at ~70 MPa) or liquefied hydrogen (8.5 MJ/L). Additionally, ammonia is a widely used raw material for agriculture fertilizer and thus has well-established storage, transport, and handling processes (about 180 million tons of ammonia are produced annually). Techno-economic analysis suggests ammonia is the least expensive fuel among hydrogen, gasoline, natural gas, liquefied petroleum gas, and methanol.

08 HYDROGEN↗

DOE OSTI2013

Head-end process for the reprocessing of HTGR spent fuel

The reprocessing of HTGR spent fuels is in favor of the sustainable development of nuclear energy to realize the maximal use of nuclear resource and the minimum disposal of nuclear waste. The head-end of HTGR spent fuels reprocessing is different from that of the LWR spent fuels reprocessing because of the difference of spent fuel structure. The dismantling of the graphite spent fuel element and the highly effective dissolution of fuel kernel is the most difficult process in the head end of the reprocessing. Recently, some work on the head-end has been done in China. First, the electrochemical method with nitrate salt as electrolyte was studied to disintegrate the graphite matrix from HTGR fuel elements and release the coated fuel particles, to provide an option for the head-end technology of reprocessing. The results show that the graphite matrix can be effectively separated from the coated particle without any damage to the SiC layer. Secondly, the microwave-assisted heating was applied to dissolve the UO{sub 2} kernel from the crashed coated fuel particles. The ceramic UO{sub 2} as the solute has a good ability to absorb the microwave energy. The results of UO{sub 2} kernel dissolution from crushed coated particles by microwave heating show that the total dissolution percentage of UO{sub 2} is more than 99.99% after 3 times cross-flow dissolution with the following parameters: 8 mol/L HNO{sub 3}, temperature 100 Celsius degrees, initial ratio of solid to liquid 1.2 g/ml. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2020

Ceramic encapsulated metal phase change material for high temperature thermal energy storage

Thermal energy storage (TES) is a broad-based technology for reducing CO₂ emissions and advancing concentrating solar, fossil, and nuclear power through improvements in efficiency and economics. Phase change materials (PCMs) are of interest as TES media because of their ability to store large amounts of heat in relatively small volumes. The volume expansion during a phase change, typically between a solid and liquid, can cause breakage of protective coatings. This paper reports on the fabrication of a ceramic encapsulated metal (CEM) high temperature TES technology using a rotary calcining furnace and a fluidized bed chemical vapor deposition coating technique. Aluminum beads were chosen as the PCM because Al has a high melting point (660 °C), low cost, high heat of fusion, and an ability to form a thin, strong alumina layer capable of supporting the Al melt for subsequent processing. Quite remarkably, this study shows that 1 mm diameter Al can be fluidized up to at least 1500 °C in an appropriate atmosphere while maintaining a spheroid geometry. This allowed for producing a first of a kind CEM whereby Al particles were encapsulated in pyro-carbon (PyC) and high purity, dense chemical vapor deposited SiC. The CEM with a PyC only coating was exposed to thermal cycling to test the performance with a differential scanning calorimeter; the melting point and latent heat were measured to be 648.4 ± 2.8 °C and 293.3 ± 6.2 J/g respectively. It was demonstrated that the CEM design is possible to produce, laying the foundation for manufacturing of high temperature, tunable, TES media.

25 ENERGY STORAGE↗