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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 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
NASA NTRS2004

Role of EIS in Materials and Coatings Selection for NASA's Launch Facilities

Corrosion studies began at NASA's John F. Kennedy Space Center (KSC) in 1966, during the Gemini/Apollo Programs, with the evaluation of long-term anti-corrosion coatings for carbon steel structures. NASAIKSC's Atmospheric Exposure Test Site was established at that time on the beach near the launch pad. In the years that followed, numerous studies at the site have identified materials, coatings, and maintenance procedures for launch hardware and equipment exposed to the highly corrosive environment at the launch pad. The atmosphere at the launch pad is highly corrosive due to the proximity of the Atlantic Ocean, high heat from rocket exhaust, and since the introduction of the Space Shuttle, the acidic combustion products of the Solid Rocket Boosters (SRBs). Currently, NASAIKSC maintains about $2 billion worth of unique equipment and facilities, not including the orbiters, each valued at about $1.8 billion. Among the items: two launch complexes, two crawler transporters, three mobile launch platforms, and specialized testing equipment. Atmospheric exposure provides very valuable data but it takes a long time and relies on human visual inspection. NASA Technical Standard for Protective Coatings requires 18 months of good performance at the Atmospheric Exposure Test Site for preliminary approval and continued good performance for 5 years for final approval of a coating system. The use of electrochemical impedance spectroscopy (EIS) was introduced at KSC in 1989 as a supplement to the traditional dc electrochemical techniques and atmospheric exposure studies. This paper presents and overview of several projects in which EIS was used in order to select materials and coatings to be used at NASA's launch facilities [1-2].

Calle, Luz Marina↗
NASA NTRS2005

RP-1 Thermal Stability and Copper Based Materials Compatibility Study

A series of electrically heated tube tests was performed at the NASA Glenn Research Center s Heated Tube Facility to investigate the effect that sulfur content, test duration, and tube material play in the overall thermal stability and materials compatibility characteristics of RP-1. Scanning-electron microscopic (SEM) analysis in conjunction with energy dispersive spectroscopy (EDS) were used to characterize the condition of the tube inner wall surface and any carbon deposition or corrosion formed during these runs. Results of the parametric study indicate that tests with standard RP-1 (total sulfur -23 ppm) and pure copper tubing are characterized by a depostion/deposit shedding process producing local wall temperature swings as high as 500 F. The effect of this shedding is to keep total carbon deposition levels relatively constant for run times from 20 minutes up to 5 hours, though increasing tube pressure drops were observed in all runs. Reduction in the total sulfur content of the fuel from 23 ppm to less than 0.1 ppm resulted in the elimination of deposit shedding, local wall temperature variation, and the tube pressure drop increases that were observed in standard sulfur level RP-1 tests. The copper alloy GRCop-84, a copper alloy developed specifically for high heat flux applications, was found to exhibit higher carbon deposition levels compared to identical tests performed in pure copper tubes. Results of the study are consistent with previously published heated tube data which indicates that small changes in fuel total sulfur content can lead to significant differences in the thermal stability of kerosene type fuels and their compatibility with copper based materials. In conjunction with the existing thermal stability database, these findings give insight into the feasibility of cooling a long life, high performance, high-pressure liquid rocket combustor and nozzle with RP-1.

Stiegemeier, B. R.↗
DOE OSTI2024

Feasibility Study for Cathodic Protection of Waste Tanks at Hanford

The Hanford Nuclear Reservation site contains approximately 211 million liters of radioactive and chemically hazardous waste arising from nuclear weapons production, beginning with World War II, and continuing through the Cold War. The waste is stored in 177 carbon-steel underground storage tanks, of which 149 are single-shell tanks (SSTs) and the remaining are double-shell tanks (DSTs). The mission of an ongoing River Protection Project is to retrieve the waste from the underground storage tanks and then treat and immobilize (i.e., vitrify) it for disposal. Waste from the older SSTs is being progressively retrieved into the newer DSTs for storage pending treatment, immobilization, and disposal. Waste chemistry controls are in place to mitigate general corrosion, pitting corrosion, and stress corrosion cracking (SCC) and minimize corrosion risks to the carbon steel tank liners of DST at the Hanford Site. The chemistry control program focuses on preserving liner integrity while balancing the need for caustic/nitrite additions that have large downstream impacts on vitrification. Some of the DSTs store salt cake or sludge waste layers contain out-of-specification interstitial liquids that contact the primary tank bottom or sidewall. Remediation of such layers through chemical additions is not practical. At the present time, the most significant leak integrity concern at Hanford is for corrosion of the tank bottoms of DSTs where the solids layer is out of specification because of hydroxide ion depletion and consequently, pH values that are less than 12. Cathodic protection (CP) has been proposed as a possible way to protect the liners of such tanks against corrosion. The objective of this project was to investigate the feasibility of applying CP to Hanford DSTs to mitigate internal corrosion of the carbon steel tank primary liners. The scope of the project included (1) a literature review on the application of CP to storage tank systems, in general, and to waste tanks at the Savannah River Site (SRS) and Hanford, (2) a review of the finite element analysis (FEA) model recently developed to evaluate potentials for a DST, and (3) the development of a boundary element analysis (BEA) model for CP for a DST. Tank AN-107, one of the Hanford DSTs, was selected for this work because (1) the bottommost waste layer in the tank is out-of-specification, and (2) electrochemical and resistivity data, based on recent waste sampling and testing, are available for this tank. The overarching conclusion of this study is that, based on the available information, it is feasible to apply CP to mitigate internal corrosion of the primary liners of the Hanford DSTs. However, significant additional information and work are required before a CP system can be designed. Recommendations for next steps in the design of the CP system will be presented.

WIERSMA, BRUCE↗
DOE OSTI2020

Boride-Carbon Hybrid Technology to Produce Ultra-Wear and Corrosion Resistant Surfaces for Applications in Harsh Conditions (Final Technical Report)

Engineered functional surfaces play an important role to enable new products and manufacturing processes that can endure harsh service conditions such as high impact and contact loads, highly abrasive wear, extreme temperatures, and corrosive environments. Engineered surfaces can also be instrumental to improving the efficient use of energy by reducing frictional losses and extending service life. The main objective of this project was to develop a hybrid surface engineering technology that combines the advantages of a novel ultrafast boriding process with the next generation of superhard carbon coatings. The hypothesis was that this hybrid process will offer an unprecedented combination of wear and corrosion resistance, low frictional losses and affordability for treated parts so that it can be utilized in many applications. During this project, a duplex process was developed that combines the advantages of ultra-fast electrochemical boriding with those of hard tetrahedral amorphous carbon coatings. Both technologies can be combined to form a hybrid technology that is characterized by low friction and wear properties combined with corrosion and fatigue resistance. Good adhesion of both layers to each other was one main goal of this project, that has been achieved with HF1 adhesion through the Rockwell-C adhesion test. In this project, the mechanical properties of the hybrid coating were modeled through a finite-element analysis approach. We can conclude that the FEA model resembles the actual samples and be utilized to predict mechanical behavior under impacts. Based on this model, application-oriented load conditions can be simulated for optimal layer design regarding thickness and mechanical properties. To exemplify, one conclusion that can be drawn from the nanoindentation model is a boride layer thickness of 50 µm is sufficient to effectively support the carbon coating on the identified AISI 1045 low carbon steel substrate material. The duplex treatment yields wear rates as low as 6 x 10 -8 mm 3 N -1 m -1 and a coefficient of friction of 0.14 when tested against a steel counter face in a ball-on-disk test setup. On the other hand, the wear rate of the only-borided AISI 1045 steel was 5 x 10 -5 mm 3 N -1 m -1 , about three orders of magnitude higher than the duplex coating. At the same time, duplex treated samples experience corrosion resistance, which could not be achieved with single-layer carbon coatings. The developed surface treatment withstands a 3-hour exposure to 15% HCl, while the only carbon coated counter sample shows severe delamination of the coating due to pin hole corrosion. The boride layer is chemically stable and pin hole free because it is formed through an electrochemical process under high current densities (700 mA/cm 2 ) and high temperature. Additionally, the hybrid coating led to at least 3x increase in fatigue strength of the steel substrate, which exceeds the target performance of 30% improvement. There are numerous potential applications for the duplex coatings. A representative application is bearing ball coatings for off-shore windmills. Compared to currently employed surface technologies in this field, the initial costs of applying our technology might be higher due to more process steps but the performance benefits lead to an increased life time of treated parts, which will lower the maintenance and replacement costs in the long-term. To validate the technology for this specific application, the team is currently investigating the process of white etching crack initiation of the duplex coating in collaboration with ANL. Overall, this project successfully validated that the boride-carbon hybrid technology can withstand harsh conditions. One possible approach to commercialization under consideration is to transfer the technology to a startup or an existing coatings company.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Characterization of the structure and chemistry of the solid–electrolyte interface by cryo-EM leads to high-performance solid-state Li-metal batteries

Solid-state lithium-metal (Li 0 ) batteries are gaining traction for electric vehicle applications because they replace flammable liquid electrolytes with a safer, solid-form electrolyte that also offers higher energy density and better resistance against Li dendrite formation. Solid polymer electrolytes (SPEs) are highly promising candidates because of their tunable mechanical properties and easy manufacturability; however, their electrochemical instability against lithium metal (Li 0 ), mediocre conductivity, and poorly understood Li 0 /SPE interphases have prevented extensive application in real batteries. In particular, the origin of the low Coulombic efficiency (CE) associated with SPEs remains elusive, as the debate continues as to whether it originates from unfavored interfacial reactions or lithium dendritic growth and dead lithium formation. In this work, we use state-of-the-art cryo-electromicroscopy (cryoEM) imaging and spectroscopic techniques to characterize the structure and chemistry of the interface between Li 0 and a polyacrylate-based SPE. Contradicting the conventional knowledge, we find that no protective interphase forms, owing to the sustained reactions between deposited Li dendrites and polyacrylic backbones and succinonitrile plasticizer. Due to the reaction induced volume change, large amounts of cracks form inside the Li dendrites with a stress corrosion-cracking behavior, indicating that Li0cannot be passivated in this SPE system. Based on this observation, we then introduce additive engineering leveraging on the knowledge of liquid electrolytes, and demonstrate that the Li 0 surface can be effectively protected against corrosion using fluoroethylene carbonate (FEC), leading to densely packed Li 0 domes with conformal and stable solid-electrolyte interphases (SEIs) films. Owing to the high room temperature ionic conductivity of 1.01 mS/cm -1 , the high transference number of 0.57 and the stabilized lithium electrolyte interface, this improved new SPE delivers an excellent lithium plating/stripping CE of 99% and 1800 hours of stable cycling in Li||Li symmetric cells (0.2 mA/cm -2 , 1mAh/cm -2 ). Furthermore, this improved cathodic stability along with the high anodic stability enables record high cycle life of >2000 cycles for Li||LiFePO 4 and >400 cycles for Li||LiCoO 2 full cells.

25 ENERGY STORAGE↗
DOE OSTI2024

Long-Term Performance of Reference Electrodes in Alkaline Radioactive Waste Storage Environments

Accurate measurements of corrosion potential are important for assessing the likelihood of internal localized corrosion and stress corrosion cracking of carbon steel tanks used for storing radioactive wastes. Reference electrodes in underground radioactive waste storage tanks are challenging to deploy, and more difficult to extract and replace frequently due to radiological exposure and disposal constraints. Hence, electrodes that exhibit stable performance over long periods of immersion in these waste environments are desirable. The present study evaluates the stability of reference electrodes used in radioactive waste storage tanks over a much longer period than previously studied. Long-term tests on Ag/AgCl and Hg/HgO reference electrodes were performed in nonradioactive simulants formulated from wastes stored at the Hanford site. Electrode degradation, which was studied by various in situ and ex situ evaluation techniques, was correlated to changes in electrode fill chemistry from waste intrusion via the porous frit junction. An intentional contamination study was performed to better understand and predict contamination effects on electrode potential drift.

Materials Science↗
NASA NTRS1981

Survey on aging on electrodes and electrocatalysts in phosphoric acid fuel cells

The processes which contribute to the decay in performance of electrodes used in phosphoric acid fuel cell systems are discussed. Loss of catalytic surface area, corrosion of the carbon support, electrode structure degradation, electrolyte degradation, and impurities in the reactant streams are identified as the major areas for concern.

Stonehart, P.↗
NASA NTRS1988

Rate of production, dissolution and accumulation of biogenic solids in the ocean

The equatorial current system, by its response to global circulation changes, provides a unique recording mechanism for long range climatic oscillations. A permanent record of the changes in rate of upwelling and organic production is generated in the equatorial deep sea sediments, particularly by such biogenic components which are unaffected by secondary dissolution. In order to determine the rates of accumulation of various sedimentary components, a reliable differential measurement of age of the strata must be obtained. Various approaches to this problem are reviewed, and sources of error discussed. Secondary dissolution of calcium carbonate introduces a substantial and variable difference between the dissolution-modified, and hence a priori unknown, rate of deposition on one hand and the rate of accumulation, derivable from the observed concentration, on the other. The cause and magnitude of these variations are of importance, particularly since some current dating schemes are based on assumed constancy in the rate of accumulation of this and, in some cases, also all other sedimentary components. The concepts used in rate evaluation are discussed with emphasis on the difference between the state of dissolution, an observable property of the sediment, and the rate of dissolution, a parameter that requires deduction of the carbonate fraction dissolved, and of the time differential. As a most likely cause of the enhanced state of dissolution of the interglacial carbonate sediments is proposed the lowered rates of biogenic production and deposition, which cause longer exposure of the carbonate microfossils to corrosion in the bioturbated surface layer of the sediment. Historical perspective is included in the discussion in view of the dedication of the Symposium to Hans Pettersson, the leader of the Swedish Deep Sea Expedition 1947-1948, an undertaking that opened a new era in deep sea research and planetary dynamics.

NASA Discipline Exobiology↗
DOE OSTI2025

Initiation of dusting corrosion in high-temperature alloys under CO exposure

Carbon monoxide is commonly encountered in energy systems, yet its reactivity with structural alloys—critical heat-resistant components in these systems—has been largely overlooked compared to the well-documented effects of oxidizing gases. In contrast, we demonstrate the high-temperature reaction of CO with NiAl using in-situ low-energy electron microscopy and X-ray photoemission electron microscopy. Our results show that CO dissociates into atomic oxygen and carbon, resulting in two concurrent reactions: selective oxidation of aluminum to form Al 2 O 3 and the initiation of dusting corrosion through carbon dissolution into the alloy and subsequent carbon deposition on the surface. These reactions produce spatially distinct surface products, preventing the formation of a continuous protective Al oxide layer. These results reveal a preference for the dissociative pathway of CO over the classic Boudouard disproportionation reaction that forms CO 2 . These insights not only advance our understanding of CO-induced alloy degradation but also highlight the practical implications for managing alloy stability and optimizing catalysis in carbon-rich environments, such as those in petrochemical processing and hydrocarbon combustion.

36 MATERIALS SCIENCE↗
NASA NTRS1995

Storing Fluorine In Graphitelike Carbon Fibers

Fluorine stored in graphite or graphitelike carbon fibers for later release and/or use in chemical reactions. Storage in carbon fibers eliminates difficulty and risk of using high-pressure tanks and pipes to hold corrosive gas. Storage in carbon fibers makes fluorine more readily accessible than does storage as constituent of metal fluoride. Carbon fibers heated to release stored fluorine, which draws away to vessel where reacts with material to be fluorinated, possibly at temperature other than release temperature. Alternatively, material to be fluorinated mixed or otherwise placed in contact with fibers and entire mass heated to or beyond release temperature.

Hung, Ching-Cheh↗
DOE OSTI2020

Water content of carbon dioxide at hydrate forming conditions

There is an interest to ensure sub-saturated water content in lines containing carbon dioxide in applications such as enhanced oil recovery and carbon sequestration, to reduce risks of hydrate blockage and corrosion. The water content of carbon dioxide at various temperatures and pressures has been measured in the past, but there is no consistent set of measurements that could be used for carbon dioxide storage and transportation design work. The solubility of water in a carbon dioxide rich gas phase at hydrate forming conditions was measured in this work. Pressures ranged from 12.06 to 29.30 bar along two isotherms, 1 °C and -7 °C, all within the gaseous carbon dioxide and hydrate stability zone. For the first time in these types of measurements, the solid phase was also characterized and confirmed to be carbon dioxide hydrate via X-ray computed tomography, simultaneous with water content measurements of the gas phase. Once carbon dioxide hydrate conversion had reached a maximum value (65% estimated by X-ray computed tomography), the equilibrium water content was measured. Prior to reaching this maximum carbon dioxide hydrate conversion, the water content in carbon dioxide was observed to decrease as liquid water converted to carbon dioxide hydrate. Furthermore, this slow conversion to hydrate, metastability of the hydrate phase, or unexpected phases may be responsible for the large discrepancy between prior data sets for similar carbon dioxide water content measurements.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1985

Carbon granule probe microphone for leak detection

A microphone which is not subject to corrosion is provided by employing carbon granules to sense sound waves. The granules are packed into a ceramic tube and no diaphragm is used. A pair of electrodes is located in the tube adjacent the carbon granules and are coupled to a sensing circuit. Sound waves cause pressure changes on the carbon granules which results in a change in resistance in the electrical path between the electrodes. This change in resistance is detected by the sensing circuit. The microphone is suitable for use as a leak detection probe in recovery boilers, where it provides reliable operation without corrosion problems associated with conventional microphones.

Parthasarathy, S. P.↗
DOE OSTI2025

Investigation of the Mechanical Degradation of Zinc-Based Cold Spray Coatings for Steel Pipelines

Internal corrosion in wet natural gas is a big challenge in the oil and gas industry due to corrosive constituents such as carbon dioxide (CO2), hydrogen sulfide (H2S), other forms of sulfur, and water in the gas stream. To mitigate internal corrosion, zinc-based cold spray coatings were designed for use in natural gas pipelines to increase the lifespan of the pipeline network. However, one of the requirements in designing internal coatings is the resistance of the coatings to mechanical forces applied on the pipeline's internal wall during pigging operations. These forces are primarily compressive and shear/friction forces. This study examines material properties that must be considered when evaluating mechanical considerations.

adhesion↗
DOE OSTI2025

Investigation of the Mechanical Degradation of Zinc-Based Cold Spray Coatings for Steel Pipelines

Internal corrosion in wet natural gas is a big challenge in the oil and gas industry due to corrosive constituents such as carbon dioxide (CO2), hydrogen sulfide (H2S), other forms of sulfur, and water in the gas stream. To mitigate internal corrosion, zinc-based cold spray coatings were designed for use in natural gas pipelines to increase the lifespan of the pipeline network. However, one of the requirements in designing internal coatings is the resistance of the coatings to mechanical forces applied on the pipeline's internal wall during pigging operations. These forces are primarily compressive and shear/friction forces. This study examines material properties that must be considered when evaluating mechanical considerations. To determine the viability of the developed coatings with respect to the shear/friction forces, the shear adhesion and wear resistance of the materials have been evaluated. Shear adhesion testing was performed with modified clevises to determine the shear stress required to cause adhesion failure at the coating/substrate interface. Scanning electron microscopy was utilized to characterize the interfaces after failure. Wear testing was performed on coatings and pipeline materials utilizing pin-on-drum testing. These tests display the stress limitations and wear that the coatings can tolerate from pigging.

mechanical degradation↗
NASA NTRS2013

The Behavior of Environmentally Friendly Corrosion Preventative Compounds in an Aggressive Coastal Marine Environment

The shift to use environmentally friendly technologies throughout future space-related launch programs prompted a study aimed at replacing current petroleum and solvent-based Corrosion Preventive Compounds (CPCs) with environmentally friendly alternatives. The work in this paper focused on the identification and evaluation of environmentally friendly CPCs for use in protecting flight hardware and ground support equipment from atmospheric corrosion. The CPCs, while a temporary protective coating, must survive in the aggressive coastal marine environment that exists throughout the Kennedy Space Center, Florida. The different protection behaviors of fifteen different soft film CPCs, both common petroleum-based and newer environmentally friendly types, were evaluated on various steel and aluminum substrates. The CPC and substrate systems were subjected to atmospheric testing at the Kennedy Space Center's Beachside Atmospheric Corrosion Test Site, as well as cyclic accelerated corrosion testing. Each CPC also underwent physical characterization and launch-related compatibility testing . The initial results for the fifteen CPC systems are reported : Key words: corrosion preventive compound, CPC, spaceport, environmentally friendly, atmospheric exposure, marine, carbon steel, aluminum alloy, galvanic corrosion, wire on bolt.

Montgomery, Eliza L.↗