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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 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
NASA NTRS2006

Preliminary Investigations of Joining Technologies for Attaching Refractory Metals to Ni-Based Superalloys

In this study, a range of joining technologies has been investigated for creating attachments between refractory metal and Ni-based superalloys. Refractory materials of interest include Mo-47%Re, T-111, and Ta-10%W. The Ni-based superalloys include Hastelloy X and MarM 247. During joining with conventional processes, these materials have potential for a range of solidification and intermetallic formation-related defects. For this study, three non-conventional joining technologies were evaluated. These included inertia welding, electro-spark deposition (ESD) welding, and magnetic pulse welding (MPW). The developed inertia welding practice closely paralleled that typically used for the refractory metals alloys. Metallographic investigations showed that forging during inertia welding occurred predominantly on the nickel base alloy side. It was also noted that at least some degree of forging on the refractory metal side of the joint was necessary to achieve consistent bonding. Both refractory metals were readily weldable to the Hastelloy X material. When bonding to the MarM 247, results were inconsistent. This was related to the higher forging temperatures of the MarM 247, and subsequent reduced deformation on that material during welding. ESD trials using a Hastelloy X filler were successful for all material combinations. ESD places down very thin (5- to 10- m) layers per pass, and interactions between the substrates and the fill were limited (at most) to that layer. For the refractory metals, the fill only appeared to wet the surface, with minimal dilution effects. Microstructures of the deposits showed high weld metal integrity with maximum porosity on the order of a few percent. Some limited success was also obtained with MPW. In these trials, only the T-111 tubes were used. Joints were possible for the T-111 tube to the Hastelloy X bar stock, but the stiffness of the tube (resisting collapse) necessitated the use of very high power levels. These power levels resulted in damage to the equipment (concentrator) during welding. It is of note that the joint made showed the typical wavy bond microstructure associated with magnetic pulse/explosion bond joints. Joints were not possible between the T-111 tube and the MarM 247 bar stock. In this case, the MarM 247 shattered before sufficient impact forces could be developed for bonding.

Gould, Jerry E.↗
NASA NTRS1979

Development and evaluation of die and container materials. Low cost silicon solar array project

Specific compositions of high purity silicon aluminum oxynitride (Sialon) and silicon beryllium oxynitride (Sibeon) solid solutions were shown to be promising refractory materials for handling and manipulating solar grade silicon into silicon ribbon. Evaulation of the interaction of these materials in contact with molten silicon indicated that solid solutions based upon beta-Si3N4 were more stable than those based on Si2N2O. Sibeon was more resistant to molten silicon attack than Sialon. Both materials should preferably be used in an inert atmosphere rather than under vacuum conditions because removal of oxygen from the silicon melt occurs as SiO enhances the dissolution of aluminum and beryllium. The wetting angles of these materials were low enough for these materials to be considered as both die and container materials.

Wills, R. R.↗
NASA NTRS1977

Method of crystallization

A method is described for refining or growing bulk single crystals in an environment substantially free of gravity. The base material is suspended, positioned, and shaped as a containerless melt by wetting forces. Because no crucible is required, high temperature refractory materials can be processed.

Walter, H. U.↗
DOE OSTI2016

Novel Functionally Graded Thermal Barrier Coatings in Coal-Fired Power Plant Turbines

This project presents a detailed investigation of a novel functionally graded coating material, pyrochlore oxide, for thermal barrier coating (TBC) in gas turbines used in coal-fired power plants. Thermal barrier coatings are refractory materials deposited on gas turbine components, which provide thermal protection for metallic components at operating conditions. The ultimate goal of this research is to develop a manufacturing process to produce the novel low thermal conductivity and high thermal stability pyrochlore oxide based coatings with improved high-temperature durability. The current standard TBC, yttria stabilized zirconia (YSZ), has service temperatures limited to <1200°C, due to sintering and phase transition at higher temperatures. In contrast, pyrochlore oxide, e.g., lanthanum zirconate (La 2 Zr 2 O 7 , LZ), has demonstrated lower thermal conductivity and better thermal stability, which are crucial to high temperature applications, such as gas turbines used in coal-fired power plants. Indiana University – Purdue University Indianapolis (IUPUI) has collaborated with Praxair Surface Technologies (PST), and Changwon National University in South Korea to perform the proposed research. The research findings are critical to the extension of current TBCs to a broader range of high-temperature materials and applications. Several tasks were originally proposed and accomplished, with additional new opportunities identified during the course of the project. In this report, a description of the project tasks, the main findings and conclusions are given. A list of publications and presentations resulted from this research is listed in the Appendix at the end of the report.

20 FOSSIL-FUELED POWER PLANTS↗
NASA NTRS2001

Self-assembling amphiphilic molecules: Synthesis in simulated interstellar/precometary ices

Interstellar gas and dust constitute the primary material from which the solar system formed. Near the end of the hot early phase of star and planet formation, volatile, less refractory materials were transported into the inner solar system as comets and interplanetary dust particles. Once the inner planets had sufficiently cooled, late accretionary infall seeded them with complex organic compounds [Oro, J. (1961) Nature (London) 190, 389-390; Delsemme, A. H. (1984) Origins Life 14, 51-60; Anders, E. (1989) Nature (London) 342, 255-257; Chyba, C. F. & Sagan, C. (1992) Nature (London) 355, 125-131]. Delivery of such extraterrestrial compounds may have contributed to the organic inventory necessary for the origin of life. Interstellar ices, the building blocks of comets, tie up a large fraction of the biogenic elements available in molecular clouds. In our efforts to understand their synthesis, chemical composition, and physical properties, we report here that a complex mixture of molecules is produced by UV photolysis of realistic, interstellar ice analogs, and that some of the components have properties relevant to the origin of life, including the ability to self-assemble into vesicular structures.

Meteoroids↗
DOE OSTI2013

NETL- Severe Environment Corrosion Erosion Facility

NETL's Severe Environment Corrosion Erosion Facility in Albany studies how new and old materials will stand up to new operating conditions. Work done in the lab supports NETL's oxy-fuel combustion oxidation work, refractory materials stability work, and the fuels program, in particular the hydrogen membrane materials stability work, to determine how best to upgrade existing power plants.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Dissolution Behavior of Mg from Magnesia-Chromite Refractory into Al-killed Molten Steel

Magnesia-chromite refractory materials are widely employed in steel production, and are considered a potential MgO source for the generation of MgO·Al{sub 2}O{sub 3} spinel inclusions in steel melts. In this study, a square magnesia-chromite refractory rod was immersed into molten steel of various compositions held in an Al{sub 2}O{sub 3} crucibles. As the immersion time was extended, Mg and Cr gradually dissolved from the magnesia-chromite refractory, and the Mg and Cr contents of the steel melts increased. However, it was found that the inclusions in the steel melts remained as almost pure Al{sub 2}O{sub 3} because the Mg content of the steel melts was low, approximately 1 ppm. On the surface of the magnesia-chromite refractory, an MgO·Al{sub 2}O{sub 3} spinel layer with a variable composition was formed, and the thickness of the MgO·Al{sub 2}O{sub 3} spinel layer increased with the immersion time and the Al content of the steel melts. At the rod interface, the formed layer consisted of MgO-saturated MgO·Al{sub 2}O{sub 3} spinel. The MgO content decreased along the thickness direction of the layer, and at the steel melts interface, the formed layer consisted of Al{sub 2}O{sub 3}-saturated MgO·Al{sub 2}O{sub 3} spinel. Therefore, the low content of Mg in steel melts and the unchanged inclusions were because of the equilibrium between Al{sub 2}O{sub 3}-saturated MgO·Al{sub 2}O{sub 3} layer and Al{sub 2}O{sub 3}. In addition, the effects of the Al and Cr contents of the steel melts on the dissolution of Mg from the magnesia-chromite refractory are insignificant.

36 MATERIALS SCIENCE↗
NASA NTRS1988

Ceramic Fabric Coated With Silicon Carbide

Material used as high-temperature shell. Ceramic fabric coated with silicon carbide (SiC) serves as tough, heat-resistant covering for other refractory materials. Developed to protect reusable insulating tiles on advanced space transportation systems. New covering makes protective glaze unnecessary. Used on furnace bricks or on insulation for engines.

Riccitiello, S. R.↗
NASA NTRS1995

Metal colloids and semiconductor quantum dots: Linear and nonlinear optical properties

One aspect of this project involves a collaborative effort with the Solid State Division of ORNL. The thrust behind this research is to develop ion implantion for synthesizing novel materials (quantum dots wires and wells, and metal colloids) for applications in all optical switching devices, up conversion, and the synthesis of novel refractory materials. In general the host material is typically a glass such as optical grade silica. The ions of interest are Au, Ag, Cd, Se, In, P, Sb, Ga and As. An emphasis is placed on host guest interactions between the matrix and the implanted ion and how the matrix effects and implantation parameters can be used to obtain designer level optical devices tailored for specific applications. The specific materials of interest are: CdSe, CdTe, InAs, GaAs, InP, GaP, InSb, GaSb and InGaAs. A second aspect of this research program involves using porous glass (25-200 A) for fabricating materials of finite size. In this part of the program, we are particularly interested in characterizing the thermodynamic and optical properties of these non-composite materials. We also address how phase diagram of the confined material is altered by the interfacial properties between the confined material and the pore wall.

Henderson, D. O.↗
NASA NTRS1996

Momentum Transfer Studies and Studies of Linear and Nonlinear Optical Properties of Metal Colloids and Semiconductor Quantum Dots

Phase 1 of this work involved design work on a momentum transfer device. The progress on design and testing will be presented. Phase 2 involved the systematic study of the MPD thruster for dual uses. Though it was designed as a thruster for space vehicles, the characteristics of the plasma make it an excellent candidate for industrial applications. This project sought to characterize the system for use in materials processing and characterization. The surface modification on ZnCdTe, CdTe, and ZnTe will be presented. Phase 3 involved metal colloids and semiconductor quantum dots. One aspect of this project involves a collaborative effort with the Solid State Division of ORNL. The thrust behind this research is to develop ion implantation for synthesizing novel materials (quantum dots wires and wells, and metal colloids) for applications in all optical switching devices, up conversion, and the synthesis of novel refractory materials. The ions of interest are Au, Ag, Cd, Se, In, P, Sb, Ga, and As. The specific materials of interest are: CdSe, CdTe, InAs, GaAs, InP, GaP, InSb, GaSb, and InGaAs. A second aspect of this research program involves using porous glass (25-200 A) for fabricating materials of finite size. The results of some of this work will also be reported.

Collins, W. E.↗
DOE OSTI2023

Mineral detection of neutrinos and dark matter. A whitepaper

Minerals are solid state nuclear track detectors — nuclear recoils in a mineral leave latent damage to the crystal structure. Depending on the mineral and its temperature, the damage features are retained in the material from minutes (in low-melting point materials such as salts at a few hundred °C) to timescales much larger than the 4.5 Gyr-age of the Solar System (in refractory materials at room temperature). The damage features from the O (50) MeV fission fragments left by spontaneous fission of 238U and other heavy unstable isotopes have long been used for fission track dating of geological samples. Laboratory studies have demonstrated the readout of defects caused by nuclear recoils with energies as small as O (1) keV. This whitepaper discusses a wide range of possible applications of minerals as detectors for E R ≳ O (1) keV nuclear recoils: Using natural minerals, one could use the damage features accumulated over O (10) Myr–O (1) Gyr to measure astrophysical neutrino fluxes (from the Sun, supernovae, or cosmic rays interacting with the atmosphere) as well as search for Dark Matter. Using signals accumulated over months to few-years timescales in laboratory-manufactured minerals, one could measure reactor neutrinos or use them as Dark Matter detectors, potentially with directional sensitivity. Research groups in Europe, Asia, and America have started developing microscopy techniques to read out the O (1)–O (100) damage features in crystals left by O (0.1)–O (100) keV nuclear recoils. We report on the status and plans of these programs. Furthermore, the research program towards the realization of such detectors is highly interdisciplinary, combining geoscience, material science, applied and fundamental physics with techniques from quantum information and Artificial Intelligence.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2024

Glass-contact refractory of the nuclear waste vitrification melters in the United States: a review of corrosion data and melter life

The performance of the refractory lining in glass melters used for nuclear waste vitrification is critical to the melter reliability for long-term continuous operation. Monofrax® K-3, a high Cr 2 O 3 fused cast refractory material, has been widely used to build the liners of nuclear waste glass melters in the United States. Corrosion behaviour of Monofrax® K-3 refractory has been evaluated based on crucible-scale testing, inspection of the refractory components following scaled melter testing, and inspections of the Defense Waste Processing Facility (DWPF) melter refractory after service. The literature generally consists of empirical models based on short-term testing to describe refractory corrosion dependence on glass composition. Corrosion data from tests with longer testing times, at various temperatures, in the presence of molten salts, and with different redox reactions in the plenum atmosphere exist, may be insufficient to provide accurate refractory service life estimates. Additionally, the corrosion data collected under actual and scaled melter operating conditions are limited. Recommendations to achieve more direct correlation between the laboratory refractory corrosion data predictions and the observed melter service life are discussed to allow for more accurate predictions of the useful life of melter refractory linings.

Jin, Tongan↗
DOE OSTI2014

Design of Refractory Linings for Balanced Energy Efficiency, Uptime, and Capacity in Lime Kilns

The rotary kilns used by the pulp and paper industry to regenerate lime in the Kraft process are very energy intensive. Throughout the 90 s, in response to increasing fuel prices, the industry used back up insulation in conjunction with the high alumina brick used to line the burning zones of their kilns. While this improved energy efficiency, the practice of installing insulating brick behind the working lining increased the inner wall temperatures. In the worst case, due to the increased temperatures, rapid brick failures occurred causing unscheduled outages and expensive repairs. Despite these issues, for the most part, the industry continued to use insulating refractory linings in that the energy savings were large enough to offset any increase in the cost of maintaining the refractory lining. Due to the dramatic decline in the price of natural gas in some areas combined with mounting pressures to increasing production of existing assets, over the last decade, many mills are focusing more on increasing the uptime of their kilns as opposed to energy savings. To this end, a growing number of mills are using basic (magnesia based) brick instead of high alumina brick to line the burning zone of the kiln since the lime mud does not react with these bricks at the operating temperatures of the burning zone of the kiln. In the extreme case, a few mills have chosen to install basic brick in the front end of the kiln running a length equivalent to 10 diameters. While the use of basic brick can increase the uptime of the kiln and reduce the cost to maintain the refractory lining, it does dramatically increase the heat losses resulting from the increased operating temperatures of the shell. Also, over long periods of time operating at these high temperatures, damage can occur in the shell. There are tradeoffs between energy efficiency, capacity and uptime. When fuel prices are very high, it makes sense to insulate the lining. When fuel prices are lower, trading some thermal efficiency for increased uptime and capacity seems reasonable. This paper considers a number of refractory linings in an effort to develop optimized operating strategies that balance these factors. In addition to considering a range of refractory materials, the paper examines other factors such as the chain area, discharge dams and other operating variables that impact the service life of the refractory lining. The paper provides recommendations that will help mill personnel develop a strategy to select a refractory lining that is optimized for their specific situation.

Computational Modeling↗
DOE OSTI2025

Multimodal Defect Imaging of Pure Tungsten Components Fabricated via Electron Beam Powder Bed Fusion

The utilization of additive manufacturing (AM) techniques for refractory materials in high-temperature environments has significantly expanded because of the ability to fabricate geometrically complex components. Electron beam powder bed fusion (EB-PBF), which provides lower residual stress, a cleaner vacuum environment, and better efficiency for high melting point, is one of the best-suited AM methods to produce advanced refractory components. However, the property variation attributed to the heterogeneous microstructure and process-induced defects has hindered the widespread adoption of EB-PBF-produced material like tungsten. While numerous in-situ monitoring and defect detection methods have been demonstrated for EB-PBF, a workflow that compares and evaluates process-induced abnormalities from different imaging perspectives is still limited. This study examines a feature-embedded tungsten component manufactured via the EB-PBF process to demonstrate the defect detection capabilities of a multimodal defect imaging workflow. The predefined and process-induced defects are evaluated by harnessing various imaging techniques, including in-situ electron imaging, layerwise near-infrared (NIR) imaging, post-build high-energy x-ray computed tomography (CT), and conventional destructive metallography. The results highlight the strengths and limitations of distinctive defect imaging techniques concerning specific defect types, sizes, and conditions. It was found that electron imaging can provide more abnormal detection capabilities while maintaining a higher measuring accuracy, against the conventional metallography in this case study, compared with NIR and CT imaging techniques.

36 MATERIALS SCIENCE↗
DOE OSTI2012

PLANETESIMAL COMPOSITIONS IN EXOPLANET SYSTEMS

We have used recent surveys of the composition of exoplanet host stars to investigate the expected composition of condensed material in planetesimals formed beyond the snow line in the circumstellar nebulae of these systems. Of the major solid-forming elements, C and O abundances (and particularly the C/O abundance ratio) strongly affect the amounts of volatile ices and refractory phases in icy planetesimals formed in these systems. This results from these elements' effects on the partitioning of O among gas, refractory solid and ice phases in the final condensate. The calculations use a self-consistent model for the condensation sequence of volatile ices from the nebula gas after refractory (silicate and metal) phases have condensed. The resultant mass fractions (compared to the total condensate) of refractory phases and ices were calculated for a range of nebular temperature structures and redox conditions. Planetesimals in systems with sub-solar C/O should be water ice-rich, with lower than solar mass fractions of refractory materials, while in super-solar C/O systems planetesimals should have significantly higher mass fractions of refractories, in some cases having little or no water ice. C-bearing volatile ices and clathrates also become increasingly important with increasing C/O depending on the assumed nebular temperatures. These compositional variations in early condensates in the outer portions of the nebula will be significant for the equivalent of the Kuiper Belt in these systems, icy satellites of giant planets, and the enrichment (over stellar values) of volatiles and heavy elements in giant planet atmospheres.

79 ASTRONOMY AND ASTROPHYSICS↗
NASA NTRS2014

Evaluation of Geopolymer Concrete for Rocket Test Facility Flame Deflectors

The current paper presents results from a combined research effort by Louisiana Tech University (LTU) and NASA Stennis Space Center (SSC) to develop a new alumina-silicate based cementitious binder capable of acting as a high performance refractory material with low heat ablation rate and high early mechanical strength. Such a binder would represent a significant contribution to NASA's efforts to develop a new generation of refractory 'hot face' liners for liquid or solid rocket plume environments. This project was developed as a continuation of on-going collaborations between LTU and SSC, where test sections of a formulation of high temperature geopolymer binder were cast in the floor and walls of Test Stand E-1 Cell 3, an active rocket engine test stand flame trench. Additionally, geopolymer concrete panels were tested using the NASA-SSC Diagnostic Test Facility (DTF) thruster, where supersonic plume environments were generated on a 1ft wide x 2ft long x 6 inch deep refractory panel. The DTF operates on LOX/GH2 propellants producing a nominal thrust of 1,200 lbf and the combustion chamber conditions are Pc=625psig, O/F=6.0. Data collected included high speed video of plume/panel area and surface profiles (depth) of the test panels measured on a 1-inch by 1-inch giving localized erosion rates during the test. Louisiana Tech conducted a microstructure analysis of the geopolymer binder after the testing program to identify phase changes in the material.

Allgood, Daniel C.↗
NASA NTRS1995

High-Temperature Graphite/Phenolic Composite

Graphite-fiber/phenolic-resin composite material retains relatively high strength and modulus of elasticity at temperatures as high as 1,000 degrees F. Costs only 5 to 20 percent as much as refractory materials. Fabrication composite includes curing process in which application of full autoclave pressure delayed until after phenolic resin gels. Curing process allows moisture to escape, so when composite subsequently heated in service, much less expansion of absorbed moisture and much less tendency toward delamination. Developed for nose cone of external fuel tank of Space Shuttle. Other potential aerospace applications for material include leading edges, parts of nozzles, parts of aircraft engines, and heat shields. Terrestrial and aerospace applications include structural firewalls and secondary structures in aircraft, spacecraft, and ships. Modified curing process adapted to composites of phenolic with other fiber reinforcements like glass or quartz. Useful as high-temperature circuit boards and electrical insulators.

Seal, Ellis C.↗