Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Low Creep”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

The effect of aspect ratio on the mechanical behavior of Li metal in solid-state cells

The Li metal anode is necessary for solid-state batteries to dramatically exceed the energy density of state-of-the-art conventional Li-ion batteries. To enable the Li metal anode, the mechanical properties of Li metal under compression in a commercially relevant cell configuration must be determined. This work examines the compression creep behavior of Li metal coupled with a relevant model solid-state electrolyte (Li 6.5 La 3 Ta 0.5 Zr 1.5 O 12 ) and current collector (Ni) as a function of applied stress (1–10 MPa) and Li foil thickness (100–700 μm). At 1 MPa applied stress, the strain rate of all Li foil thicknesses under compression was almost four orders of magnitude lower than what is predicted from tensile creep tests. Steady-state creep behavior was observed for Li foil ≥350 μm at 5 MPa and ≥250 μm at 10 MPa. Conversely, sustained creep deformation was not observed for 100 and 150 μm Li foils at any applied stress. It is suggested that friction at the Li/LLZO and Li/Ni interfaces leads to the formation of hydrostatic stress that controls Li deformation at low aspect ratios. Finally, these results have implications for battery pack stack pressure requirements, particularly relating to void formation during stripping and Li metal filament penetration during plating.

25 ENERGY STORAGE↗
DOE OSTI2025

Thermomechanical Modeling and Analysis of a High-Temperature Light Trapping Planar Cavity Receiver

Solar energy harnessed through concentrating solar power (CSP) systems offers a promising path to sustainable energy production, with the efficiency and longevity of these systems relying on key components like solar receivers. This study analyzes the thermomechanical behavior of an innovative enclosed light-trapping solar receiver optimized for particle heating applications. The receiver utilizes sheet metal alloys to form enclosed cavities that reflect and trap incoming solar flux, as well as enclosed channels that contain fluidized particle beds absorbing solar heat. Finite element analysis (FEA) is applied to predict the receiver's thermomechanical performance under extreme solar flux conditions. Temperature distributions from a thermal model simulating a multi-panel assembly at steady state are input into the FEA thermomechanical model for stress analysis. A key aspect of the analysis focuses on evaluating creep-fatigue damage, with a design target of achieving a 30- year service life. Various stress relief techniques are also proposed to extend the receiver's service life. The results highlight the significant impact of the particle-to-wall heat transfer coefficients (HTCs), ranging from 800 W/m2*K to 1400 W/m2*K. The 800 W/m2*K case shows a maximum von Mises stress of 164 MPa, while the 1400 W/m2*K case reduces it to 150 MPa. The creep life increases from 4,000 hrs in the 800 W/m2*K case to over 100,000 hrs in the 1400 W/m2*K case with Inconel 740H used, indicating that higher HTCs reduce stress and extend lifespan. This research advances the design of high-efficiency, low-stress solar receivers for particle-based thermal energy storage in CSP and industrial heating applications.

concentrating solar power↗
DOE OSTI2022

Materials Genomics Search for Possible Helium‐Absorbing Nano‐Phases in Fusion Structural Materials

Abstract Civilian fusion demands structural materials that can withstand the harsh environments imposed inside fusion plasma reactors. The structural materials often transmute under 14.1 MeV fast neutrons, producing helium (He), which embrittles the grain boundary (GB) network. Here, it is shown that neutron‐friendly and mechanically strong nano‐phases with atomic‐scale free volume can have low He‐embedding energy and >10 at.% He‐absorbing capacity, and can be especially advantageous for soaking up He on top of resisting radiation damage and creep, provided they have thermodynamic compatibility with the matrix phase, satisfactory equilibrium wetting angle, as well as a high enough melting point. The preliminary experimental demonstration proves that is a good ab initio predictor of He shielding potency in nano‐heterophase materials, and thus, is used as a key feature for computational screening. In this context, a list of viable compounds expected to be good He‐absorbing nano‐phases is presented, taking into account , the neutron absorption and activation cross‐sections, the elastic moduli, melting temperature, the thermodynamic compatibility, and the equilbrium wetting angle of the nano‐phases with the Fe matrix as an example.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Implications of carbon content for the processing, stability, and mechanical properties of cast and wrought Ni-based superalloy Nimonic 105

As the temperature and pressure requirements in land-based turbines for power generation increase, the shift towards more advanced alloys, e.g., Ni-based superalloys, requires improved understanding of their long-term stability and mechanical properties. Additionally, the larger size of the components also presents fabrication and cost-reduction problems. In this study, we investigated Nimonic 105 as a potential rotor material at two carbon content levels – the commonly used maximum of the alloy specification and a lower carbon content variant. Reducing the carbon content presented fabrication challenges, resulting in surface crack formation during hot working. Additionally, a lower M 6 C carbide fraction was present after fabrication/solutioning, leading to a significantly larger grain size. After the standard aging treatment, similar γ' populations formed in the two variants, however the M 6 C carbides in the high-carbon variant already started transforming to intergranular M 23 C 6 . Although we did not observe a noticeable effect on the tensile properties of the two variants, the lower carbon content alloy possessed a superior creep property – mainly due to the larger grain size as the microstructural stability was inferior. Further, upon prolonged thermal exposure, the M 6 C carbides in the low-carbon variant further decomposed to intergranular and intragranular σ and μ precipitates, as opposed to mainly M 23 C 6 as in the high-carbon variant.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Effect of stress on Laves phase precipitation in creep ruptured Grade 92 ferritic martensitic steel characterized by a novel accessible method

At high temperature conditions relevant to fossil and nuclear energy plants, Laves phase (Fe 2 X, X=Mo, W) precipitation is observed in common ferritic martensitic (FM) structural steels, with various reported effects on creep behavior. Despite being valuable metrics to correlate with mechanical properties and other precipitate phases, the volume fraction and number density of Laves phase precipitates has been difficult to quantify accurately using common techniques such as transmission electron microscopy (TEM) due to the relatively large size (∼0.25 μm) and low number density (∼10 11 cm −3 ) of Laves precipitates. Here, to address this characterization challenge, we developed and demonstrated a high-throughput and widely accessible method to quantify the volume fraction and number density of the Laves phase based on scanning electron microscope (SEM) images with a backscattered electron signal and the information depth (ID) of backscattered electrons. We applied this new technique in creep ruptured Grade 92 FM steel to study the effect of Laves phase on creep properties and determine the influence of stress on Laves phase precipitation. The quantitative accuracy of the SEM-based volume fraction and number density values was verified using synchrotron high energy X-ray diffraction and serial sectioning tomography. Stress did not significantly affect the Laves phase size or volume fraction during creep testing at 550 – 650°C and stress levels of 90 – 260 MPa (vs. unstressed conditions). Conversely, a moderate but statistically significant stress-enhanced increase in Laves phase number density, corresponding to an increase in nucleation rate, occurred during creep exposure above 110 MPa.

Creep↗
DOE OSTI2020

Design and Development of Low Weight, Titanium Aluminide Airfoils for High Performance Industrial Gas Turbines meeting 65% Combined Cycle Efficiency (Final Report)

This project funded under DOE-FOA-0001816 was performed with the intent of evaluating the potential of utilizing a low density, high specific strength Titanium Aluminide (TiAl) alloy in a large annulus last stage gas turbine blade with the intent of improving combined cycle gas turbine efficiency toward a goal of reaching 65% efficiency. The project consisted of identifying a potentially suitable TiAl material for manufacture of such a large blade by investment casting. This included estimation of design properties for the selected alloy, trade studies using a baseline design created for a nickel based alloy cast in the TiAl alloy to evaluate potential design changes required for the use of this material and optimization of a prototype design for the same baseline application using the selected TiAl alloy. Several rounds of optimization were completed with the intent of meeting the baseline design targets with a resulting design that showed at least equivalent performance in terms of creep, LCF/TMF, HCF and aerodynamic damping potential. While it was found that significant reductions in blade loading on the disk were possible, the design resulting from the optimization met most lifing targets at the baseline size, but showed a reduction in margins in some areas in comparison to the Ni-based baseline design. Additionally, it was found that the low strain tolerance of the TiAl alloy for temperatures at and below the operational temperature of the attachment resulted in marginal, although still acceptable, creep rupture performance of the design. Due to results indicating the reduced potential for increasing turbine annulus compared to expectations a Phase II award was not proposed and it is not recommended to pursue additional design optimization efforts until further material advances with TiAl materials are achieved.

03 NATURAL GAS↗
DOE OSTI2021

Mechanical Behavior of High-Entropy Alloys: A Review

High-entropy alloys (HEAs) are materials that consist of equimolar or near-equimolar multiple principal components but tend to form single phases, which is a new research topic in the field of metallurgy, and have attracted extensive attention in the past decade. The HEAs families contain the face-centered-cubic (fcc), body-centered-cubic (bcc), and hexagonal-close-packed (hcp)-structured HEAs. On the one hand, mechanical properties, e.g., hardness, strength, ductility, fatigue, and elastic moduli, are essential for practical applications of HEAs. Scientists have explored in this direction since the advent of HEAs. On the other hand, the pursuit of high strength and good plasticity is the critical research issue of materials. Hence, strengthening of HEAs is a crucial issue.In this chapter, we reviewed the recent work on the room-temperature elastic properties and mechanical behavior of HEAs, including the mechanisms behind the plastic deformation of HEAs at both low and high temperatures. Furthermore, the present work examined the strengthening strategies of HEAs, e.g., strain hardening, grain-boundary strengthening, solid-solution strengthening, and particle strengthening. The fatigue, creep, and fracture properties were briefly introduced. Lastly, the future scientific issues and challenges of HEAs were discussed.

Shang, Yuanyuan↗
DOE OSTI2025

In situ self-ion (Fe + ) irradiation of ODS-FeCrAl alloy fuel cladding materials with different Cr contents: The early stages of Cr-rich α’ phase precipitation

Oxide-dispersion-strengthened FeCrAl (ODS-FeCrAl) alloys are candidate accident-tolerant fuel cladding materials for light water reactors because they demonstrate satisfactory resistance to materials degradation effects such as high-temperature oxidation, radiation-induced swelling, and creep. Their perspective deployment to market is challenged, however, by their inherent susceptibility to irradiation embrittlement caused by the precipitation of the brittle Cr-rich α’ phase at relatively low temperatures (≤475 °C). This work used in situ self-ion irradiation (150 keV Fe + ) in a transmission electron microscope to elucidate the early stages of Cr-rich α’ phase precipitation in three candidate ODS-FeCrAl alloy fuel cladding materials with different Cr contents (10, 12, and 20 wt.%) and microstructures. The early stages of the process resulting in the precipitation of the Cr-rich α’ phase in these three ODS-FeCrAl alloys under Fe + irradiation were investigated at room temperature and 300 °C up to total fluences of 1.7 × 10 15 ions·cm -2 (2 dpa) and 3.4 × 10 15 ions·cm -2 (4 dpa), using three damage dose rates (5 × 10 –5 , 3.3 × 10 –4 , and 2 × 10 –3 dpa·s -1 ). Post-irradiation examination via scanning transmission electron microscopy, energy-dispersive X-ray spectroscopy and electron energy loss spectroscopy suggested that the precipitation of the Cr-rich α’ phase might be promoted by the phase separation of the alloy matrix into Cr-rich and Fe-rich regions. Interestingly, oxygen impurities segregated preferentially in the Cr-rich regions, possibly promoting the radiation-assisted formation of the Cr-rich α’ phase. α’ phase precipitation was more pronounced at room temperature when compared to 300 °C, and it was clearly promoted by the progressive increase in the Cr content of the ODS-FeCrAl alloy.

36 MATERIALS SCIENCE↗
DOE OSTI2020

The compositional optimization and secondary phases evaluation regarding the creep resistance in Grade 91 steel through the CALPHAD approach

The critical secondary phases along with critical temperatures in regard to the creep resistance of Grade 91 steel alloy were evaluated in order to optimize the composition of the alloy to improve the creep resistance. The critical temperatures which are highlighted in this paper are Ac1 (the threshold temperature in which austinite begins to form), and Ac3 (the threshold temperature at which ferrite is fully transformed into austenite). Furthermore, optimization was presented through various Cr, V, Nb, and N concentrations in Gr.91 in relation to these critical temperatures and the mole fraction of M 23 C 6 , MX, and Z-Phase as critical secondary phases. Here, the results indicate that increasing V and Nb will increase MX stability, whereas decreasing Cr and N lead to a decrease in Z-Phase and M 23 C 6 stability, which may lead to an increased creep resistance of the material. Upon further analyzing the V, Nb, and N concentrations in Gr.91, results indicate that increasing Nb content in the steel can lead to an increased stability of Nb-rich MX2 carbide which can be used to replace Z-Phase in low N steels. Simulation results indicate that elimination of N with a dramatic increase in Nb concentrations result in the stability increase of only M 23 C 6 and MX2 phases at temperature regions between 600 °C and 1370 °C and a complete removal of Z-Phase precipitation. Overall, with the elimination of N, which destabilizes Z-Phase precipitation, and an increase in Nb for NbC carbide stability, a possible solution to increasing both long-term and short-term creep resistance for Gr.91 can be achieved, though further optimization and creep experiments need to be conducted for final conclusions.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Compaction of crushed salt for safe containment – overview of the KOMPASS project

Abstract. In Germany, rock salt formations are possible host rock candidates for a repository for heat-emitting radioactive waste. The safety concept of a repository in salt bases on a multibarrier system consisting mainly of the geological barrier salt and geotechnical seals ensuring safe containment. Crushed salt will be used for backfilling of cavities and sealing measures in drifts and shafts due to its favourable properties and its easy availability (mined-off material). The creep of the rock salt leads to crushed salt compaction with time. Thereby, the crushed salts' porosity is reduced from the initial porosity of 30 %–40 % to a value comparable to the porosity of undisturbed rock salt (≤1 %). In such low porosity ranges, technical impermeability is assumed. The compaction behaviour of crushed salt is rather complex and involves several coupled THM processes (Kröhn et al., 2017; Hansen et al., 2014). It is influenced by internal properties like humidity and grain size distribution, as well as boundary conditions such as temperature, compaction rate or stress state. However, the current process understanding has some important gaps referring to the material behaviour, experimental database and numerical modelling. It needs to be extended and validated, especially in the low porosity range. The objective of the KOMPASS project was development of methods and strategies for the reduction of deficits in the prediction of crushed salt compaction leading to an improvement of the prognosis quality. Key results are as follows (KOMPASS Phase 1, 2020): selection of an easily available and permanently producible synthetic crushed salt mixture, acting as a reference material for generic investigations; development and proof of different techniques for producing pre-compacted samples for further investigations; establishment of a tool of microstructure investigation methods to demonstrate the comparability of grain structures of pre-compacted samples with in-situ compacted material for future investigations; execution of various laboratory experiments using pre-compacted samples, e.g. long-term creep tests which deliver reliable information about time- and stress-dependent compaction behaviour; development of a complex experimental investigation strategy to derive necessary model parameters considering individual functional dependencies. Its technical feasibility was successfully verified; benchmarking with various existing numerical models using datasets from three different triaxial long-term tests. The result was not entirely satisfactory; however, the number of influencing factors is small and further validation work has to be done. Overall, the KOMPASS project has made significant progress in the approaches to solving the outstanding question, building the basis for further investigations.

Friedenberg, Larissa↗
DOE OSTI2025

Design Basis Document / Owner’s Technical Specification for Nitrate Salt Systems in CSP Projects (Final Technical Report)

The number of commercial coal, gas, and nuclear projects built over the past 100 years number in the thousands. As such, there is a large database, available to a wide range of commercial engineering contractors, on proven designs. In essence, unsuccessful designs have, through generations of iterations, been identified and then deleted from further consideration. In contrast, the number of commercial parabolic trough projects using nitrate salt for the thermal storage media is perhaps 60. Further, the number of commercial central receiver projects using nitrate salt as the working fluid is on the order of 20, including estimates for China. Given the relative immaturity of salt technology, and commercial pressures to successfully bid new solar projects into a mature electricity market, solar projects often promise more than has been delivered. The Design Basis Document / Owner’s Technical Specification is a first step in the iteration process. The report describes the successful features of commercial projects, outlines a range equipment and system failures in projects that didn’t operate as intended, and provides a draft set of design changes intended to correct the known problems. The product of the study is 3 volumes of technical material; one volume is on parabolic trough technologies; a second is on central receiver technologies, and the third is on potential design changes to parabolic trough and central receiver projects. The 3 volumes, which total some 590 pages, can be found at https://www.solardynllc.com/csp-plant-technologies. One of the principal topics in the report is the use of functional or prescriptive specifications. Functional specifications describe what the equipment needs to do, consistent with the minimum legal requirements of the local jurisdictions. The details of how this is to be accomplished is developed by the engineering contractor. Prescriptive specifications, which are developed by the Owner, prescribe to the engineering contractor how the functional requirements are to be met. This arrangement ensures that the favorable experience from a previous project is repeated. One example is the design code for the hot salt tank in central receiver projects. The closest design basis is API Standard 650 Welded Steel Tanks for Oil Storage. However, the maximum design temperature in API 650 is 260 °C. As such, solar projects have typically adopted a hybrid Code approach, in which allowable material stresses are taken from ASME Section II Materials. Further, since the tanks experience daily changes in temperature and in (static) pressure, and since portions of the tank can operate at stresses beyond the elastic range, the low cycle fatigue life of the tank is conducted using the rules of Section VIII Division 2. However, in a recent study by NREL, the principal damage mechanism was identified as creep rather than fatigue. Further, design stresses permitted under Section VIII Division 2, corresponding to a fatigue life of 30 years, result in projected creep lifetimes of only 2 to 5 years. An alternate design approach, prescribed by the Owner, would be based on Code sections intended for high temperature service in the creep regime. A candidate is Section III Division 5. Granted, this is a nuclear code section, and it’s use would not likely be mandated by local jurisdictions. However, the effects of creep have been deemed to be of sufficient importance that one nuclear project developer, and one central receiver project developer, have stipulated in the tank design specification that the equipment be designed to the requirements of Section III Division 5.

14 SOLAR ENERGY↗
DOE OSTI2023

Irradiation creep measurement and microstructural analysis of chromium nitride–coated zirconium alloy using pressurized tubes

Environmental barrier coatings for Zr-based materials are currently under development to reduce oxidation and embrittlement in light-water reactors. Chromium nitride is one such candidate for this application, particularly as accident-tolerant fuel cladding. However, quantifying the impact of coatings on the irradiation-induced creep of zircaloy (Zry) is critical as this mechanism often exceeds thermal creep rates under light-water reactor operating conditions and can be a limiting design characteristic. Additionally, examining irradiation effects in the microstructure at the coating interface is key to understanding the compatibility of the material system. Here, to accelerate the experimental measurement of irradiation creep and microstructure evolution in CrN-Zry, compact, pressurized creep tubes were fabricated and irradiated in the High Flux Isotope Reactor (HFIR) at Oak Ridge National Laboratory. Miniature, thin-walled rodlets fabricated from annealed Zr-Sn barstock were coated with CrN using physical vapor deposition (PVD) to nominal thicknesses of 4 and 8 μm. Coated and uncoated rodlet specimens were internally pressurized and welded, generating nominal circumferential hoop stresses of 0, 90, or 180 MPa under 300°C irradiation conditions. Twelve specimens were measured diametrically prior to irradiation using a low-cost, automated, contactless laser profilometer developed for this work. Specimens were irradiated in sealed capsules for one 25-day HFIR cycle, accumulating approximately 1.8 $\times$ 10 21 n/cm 2 fast fluence (E n > 10 MeV). The irradiated samples were retrieved and remeasured using the same profilometry system in a shielded hot cell facility. Irradiation creep between specimens was compared using standard statistical tests and showed that both thicknesses of CrN coating had a negligible effect on the irradiation creep strain of the Zry material. Microstructure characterization of pre- and post-irradiated CrN-Zry specimens showed minimal changes due to irradiation but did show a substantial O-rich region at the Zry-CrN interface.

36 MATERIALS SCIENCE↗
DOE OSTI2022

BISON fuel performance modeling optimization for experiment X447 and X447A using axial swelling and cladding strain measurements

With the recent need to qualify new reactor designs such as the Versatile Test Reactor (VTR), fuel performance calculations need to be performed to determine safety criteria of the proposed designs. In order to validate the fuel performance results obtained by a fuel performance code, BISON, for new reactor designs, legacy fuel from EBR-II and FFTF MFF with Post -Irradiation Examination (PIE) data need to be used as validation cases to benchmark models. Here in this work, BISON has been paired with the Fuels Irradiation & Physics Database (FIPD) and IFR Materials Information System (IMIS) to supply PIE data for comparison with simulations of EBR-II experiments X447/X447A. X447/X447A were assessed by implementing models for Fuel Cladding Chemical Interaction (FCCI) within BISON and optimizing the friction coefficient between the fuel surface and the cladding, the anisotropic swelling factor, and the HT9 first thermal creep scalar (which scales the first term in the HT9 creep equation) to best match the PIE axial fuel swelling height and cladding profilometry for all pins in X447/X447A. The optimal values were found using a generic algorithm developed to select different values for the three parameters until end criteria was met and error couldn’t be reduced further. The BISON-simulated cladding profilometry was evaluated using Standard Error of the Estimate (SEE) to account for the profile shape of the cladding profilometry. Optimal values for the friction coefficient, anisotropic fuel swelling factor, and HT9 first thermal creep scalar were found to best fit the BISON simulation results to the PIE measurements found in IMIS and FIPD. Improvements to current models are suggested to account for the underprediction of fuel swelling at low burnups and the overprediction of fuel swelling at higher burnups observed for the axial fuel swelling height. Although two pins in EBR-II X447/X447A (DP70 and DP75) were known to fail due to FCCI, none of the pins simulated in BISON reached a cumulative damage fraction (CDF) above 0.008 with FCCI correlations coupled in the BISON simulations. The error estimate generated for all pins in X447/X447A using optimal values was 209 µm, which is deemed acceptable.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Report on FY 2020 Testing in Support of the Development and Extension of ASME Code Rules for Grade 91

This report summarizes the FY 2020 research and activities at Oak Ridge National Laboratory in support of the ASME code rule development and code extension for Grade 91 (Gr. 91) steel. Incorporation of the Gr. 91 temperature-dependent fatigue curves in Section III Division 5 was one major task, and the associated major aspects brought up during the course of the ASME balloting process are documented in this report. Experiments and analysis continued on the development of the alternative creep-fatigue evaluation based on elastic–perfectly plastic (EPP) plus simplified model test (SMT) methodology. The focus of the study in FY 2020 was the evaluation of the hold-time effect at high cycle and low strain range region. Baseline testing in support of the evaluation of hold time effects was started and will continue in FY 2021. Major on-going experiments and activities in support of the ASME code development and extension of Gr. 91 will be completed in FY 2021.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2021

Draft Rules for Alloy 617 Creep-Fatigue Design Using an EPP+SMT Approach

The report describes an improved new creep-fatigue design method for structural components in high temperature nuclear service. The new method uses an integrated elastic-perfectly plastic (EPP) analysis and Simplified Model Test (SMT) approach that greatly simplifies the design process by avoiding the separate evaluation of creep and fatigue damages and eliminating the requirement of stress classification. The report includes draft design rules, presented in a format compatible with an ASME nuclear Code Case, as well as a commentary on the rules and the validation of the rules using pressurized SMT (p-SMT) test data. Areas of potential improvement have been identified for further evaluation. The report also develops EPP+SMT design charts for Alloy 617 at temperatures between 800°C and 950°C by extrapolating high strain range, short hold test data to low strain range and long hold times, typical for structural components in high temperature nuclear service. The design charts are currently limited to 10,000 cycles to avoid excessive extrapolation outside the test database. More robust alternate extrapolation procedures will be considered in future work. The report includes several verification problems comparing the new EPP+SMT design method with current ASME creep-fatigue design methods. The comparison demonstrates that the EPP+SMT method significantly reduces the over-conservatism in current methods. Finally, the report includes a fully-documented sample problem with multiple load cases detailing the application of proposed EPP+SMT design rules.

36 MATERIALS SCIENCE↗
DOE OSTI2022

New High-Strength Ni-based Alloys for High Temperature Service in Liquid Fluoride Salt Environments

The ever-increasing demand for higher system thermal efficiency necessitates the operation of power generation cycles and heat conversion systems for chemical processes at progressively higher temperatures. As the system operating temperature increases, fewer and fewer materials are available with the required mechanical properties and environmental compatibility. This dearth of materials is particularly acute in structural applications at temperatures above 700°C in liquid Fluoride Salt Cooled High-Temperature Reactors (FHRs) and Concentrated Solar Power (CSP) systems where liquid fluoride and/or liquid chloride salts are used for their high thermal capacity and low thermal conductivity to store and transport heat. It has been shown that fluorides and chlorides can degrade the properties of the material used for storage and transport due to corrosive effects thus affecting the performance and lifetime characteristics. Thus, materials used for storage and transport for fluoride/chloride-salt must at the minimum have good compatibility with the salt by exhibiting low corrosion rates at the required temperatures. In addition, since many of the components will be subject to stresses in service, they need to have sufficient strength to resist plastic deformation, and the resistance to time dependent creep deformation at these temperatures, and stress levels. Achieving the combination of these properties required for higher temperatures is particularly challenging considering traditionally, the expected lifetime of some of the components used in these systems are from 30 years (CSP) to 80 years (FHRs). Although 316 stainless steel and associated redox corrosion reduction techniques are being considered for use in the first generational systems, use of 316SS is limited to operating temperatures up to ~ 650°C, thereby resulting in lower reactor efficiencies. Hastelloy ® N, developed at ORNL in the 1950s-60s for molten salt service is currently the leading candidate FHR structural alloy but has inadequate creep properties at high temperatures. Using a computationally-guided approach, Oak Ridge National Laboratory had developed new high strength alloys strengthened by γ’ precipitates (about 2X the strength of Hastelloy ® N) in small laboratory-scale heats that show good resistance to corrosion by fluorides and improved creep rupture life at temperatures up to 850°C (U.S. Patent Application No. 13/833,357 entitled “High Strength Alloys for High Temperature Service in Liquid-Salt Cooled Energy Systems”- granted U. S. Patent No. 9,540,714).

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

DESIGN AND TESTING OF A 275 BAR 700 DEGREE CELSIUS EXPANDER FOR AN INTEGRALLY GEARED SUPERCRITICAL CO2 COMPANDER

An integrally-geared (IG) compressor-expander (compander) for use in a nominal 10 MW-scale concentrated solar power (CSP) supercritical carbon dioxide (sCO2) plant application was designed, manufactured, and tested. The integrally-geared compander (IGC) developed for this application comprises multiple pinion shafts interacting through a single bull gear to create a compact package and utilize a lowcost, low-speed driver. The present work will detail the design of the high-pressure high-temperature expander casing on an integrally geared frame, and illustrate how the project successfully mitigated the risk of fatigue and creep while allowing for rapid thermal transients in the design. Furthermore, test data from the test campaign will be presented supporting the analysis. Test results also show temperature profiles during operation exceeding 720° Celsius.

wilkes, jason↗