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At least 1,441 records · Page 80
All sourcesNASA NTRSDOE OSTI
DOE OSTI2016

Energetic Study of Helium Cluster Nucleation and Growth in 14YWT through First Principles

First principles calculations have been performed to energetically investigate the helium cluster nucleation, formation and growth behavior in the nano-structured ferritic alloy 14YWT. The helium displays strong affinity to the oxygen:vacancy (O:Vac) pair. By investigating various local environments of the vacancy, we find that the energy cost for He cluster growth increases with the appearance of solutes in the reference unit. He atom tends to join the He cluster in the directions away from the solute atoms. Meanwhile, the He cluster tends to expand in the directions away from the solute atoms. A growth criterion is proposed based on the elastic instability strain of the perfect iron lattice in order to determine the maximum number of He atoms at the vacancy site. We find that up to seven He atoms can be trapped at a single vacancy. However, it is reduced to five if the vacancy is pre-occupied by an oxygen atom. Furthermore, the solute atoms within nanoclusters, such as Ti and Y, will greatly limit the growth of the He cluster. A migration energy barrier study is performed to discuss the reduced mobility of the He atom/He cluster in 14YWT.

Gan, Yingye↗
DOE OSTI2016

Fuel Performance Simulation of Iron-Chrome-Aluminum Cladding during Steady-State LWR Operation

During a severe accident scenario, such as a loss-of-coolant accident, a nuclear reactor may lose its capacity to cool its fuel. The fuel rod temperatures begin to increases, quickly reaching temperatures where the coolant begins to evaporate. This lowers the coolant level in the core and eventually uncovers the fuel. Without sufficient heat transfer from the fuel rods to the coolant, the temperature of the fuel and cladding will increase dramatically. In the case of traditional zirconium-based alloys, as the temperature of the cladding reaches ∼1200 deg. C the zirconium rapidly begins to oxidize with H{sub 2}O in the coolant and steam. This oxidation reaction causes both thinning of the Zr-alloy cladding as the metal reacts and releases large amounts of H{sub 2} gas into the reactor pressure vessel. In order to increase the safety margin of LWR fuel in severe accident scenarios, several alternative cladding materials have been proposed to replace the currently used zirconium-based alloys. Of these materials, there is a particular focus on select iron-chrome-aluminum (FeCrAl) alloys because of slower oxidation Kinetics in high temperature steam than zirconium-based alloys. This increased oxidation resistance may provide additional coping time to mitigate any further damage resulting from an accident. However, by changing the cladding material, the neutronic characteristics of the core will change. FeCrAl alloys exhibit thermal neutron absorption cross sections nearly ∼12-16 x greater than Zr-alloys. This decreases the reactivity of the core, subsequently decreasing the potential cycle length for operation. To counteract this, fissile material may be added in the form of increased enrichment or increased fuel mass or the cladding thickness might be decreased, effectively reducing the neutronic penalty from using the alloy. In this study, all three changes are considered. To assess the viability of FeCrAl as an alternative cladding to Zr-alloys, engineering-scale fuel performance analysis is used to monitor the cladding and integral fuel rod behavior through its operation. Ongoing work is being performed to identify key parameters essential to modeling FeCrAl alloys for LWR applications and properly model fuel compliance and stress relief mechanisms for UO{sub 2} fuel. To improve the predictive capability of fuel performance codes for FeCrAl cladding under normal operation, high-fidelity mechanistic/physics-based material models are needed. This information can be generated and improved by access to experimental data on targeted FeCrAl alloys. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
NASA NTRS1994

Iron alteration minerals in the visible and near-infrared spectra of low-albedo asteroids

Absorption features centered near 0.60-0.65 and 0.80-0.90 micrometers have been identified in the spectra of five low-albedo main-belt and outer-belt asteroids. These absorption features are attributed respectively to the (6)A(sub 1) goes to (4)T(sub 2)(G) and (6)A(sub 1) goes to (4)T(sub 1)(G) charge transfer transitions in minerals such as goethite, hematite, and jarosite that are products of the aqueous alteration of anhydrous silicates. A shoulder near 0.63 micrometers has also been identified in the absorption feature centered near 0.7 micrometers attributed to oxidized iron in phyllosilicates found predominantly in C- and G-class asteroids reflectance spectra. The coexistence of iron oxides with phyllosilicates in asteroids believed to have undergone aqueous alteration would be expected based upon analogy with terrestrial aqueous alteration and the observed mineralogy of carbonaceous chondrites. The number of low-albedo asteroids having only iron alteration absorption features compared to the number of low-albedo asteroids having spectral characteristics indicative of phyllosilicates is small. Either the conditions under which these asteroids formed are rare, or the iron alteration minerals could be formed in the interiors of objects where phyllosilicates dominate the surface mineralogy.

Vilas, Faith↗
NASA NTRS1980

Origins and size distribution of metallic iron particles in the lunar regolith

The metallic iron concentration has been measured in three ranges of metal particle diameters for 79 lunar soils by a combination of static magnetic and ferromagnetic resonance techniques. Based on these measurements, a model has been developed which apportions the total metallic iron content of lunar soils between three components: (1) metallic iron particles produced from the exposure-induced reduction of ferrous iron; they range from 40 to 330 A in diameter and are predominantly associated with agglutinate glass; (2) metallic iron particles derived from the metallic phases of the micrometeorites involved in the formation of agglutinate glass; these particles are mostly greater than 300 A in diameter; and (3) metallic iron particles in the source materials such as bedrock and breccias; these are usually greater than 330 A in diameter. The maximum concentration of metallic iron in lunar regolith is estimated at about 0.7 equiv. wt% in highland regions (approximately 5.0 wt% FeO) and about 1.0 equiv. wt% in mare regions (approximately 15.0 wt% FeO).

Morris, R. V.↗
NASA NTRS1983

Iron-copper metallization for flexible solar/cell arrays

The feasibility of a copper-base metallization for shallow-junction cells applied in flexible solar arrays in space is discussed. This type of metallization will reduce usage of precious metals (such as silver), increase case of bonding (by welding or by soldering) and eliminate heavy high Z interconnects (such as molybdenum). The main points of concern are stability against thermally induced diffusion of copper into silicon which causes degradation of shallow cell junctions, and low series resistance of the contact with semiconductor which promotes cell efficiency.

Lavendel, H. W.↗
NASA NTRS2015

Physics-Based Modeling of Meteor Entry and Breakup

A new research effort at NASA Ames Research Center has been initiated in Planetary Defense, which integrates the disciplines of planetary science, atmospheric entry physics, and physics-based risk assessment. This paper describes work within the new program and is focused on meteor entry and breakup.Over the last six decades significant effort was expended in the US and in Europe to understand meteor entry including ablation, fragmentation and airburst (if any) for various types of meteors ranging from stony to iron spectral types. These efforts have produced primarily empirical mathematical models based on observations. Weaknesses of these models, apart from their empiricism, are reliance on idealized shapes (spheres, cylinders, etc.) and simplified models for thermal response of meteoritic materials to aerodynamic and radiative heating. Furthermore, the fragmentation and energy release of meteors (airburst) is poorly understood.On the other hand, flight of human-made atmospheric entry capsules is well understood. The capsules and their requisite heatshields are designed and margined to survive entry. However, the highest speed Earth entry for capsules is 13 kms (Stardust). Furthermore, Earth entry capsules have never exceeded diameters of 5 m, nor have their peak aerothermal environments exceeded 0.3 atm and 1 kW/sq cm. The aims of the current work are: (i) to define the aerothermal environments for objects with entry velocities from 13 to 20 kms; (ii) to explore various hypotheses of fragmentation and airburst of stony meteors in the near term; (iii) to explore the possibility of performing relevant ground-based tests to verify candidate hypotheses; and (iv) to quantify the energy released in airbursts. The results of the new simulations will be used to anchor said risk assessment analyses. With these aims in mind, state-of-the-art entry capsule design tools are being extended for meteor entries. We describe: (i) applications of current simulation tools to spherical geometries of diameters ranging from 1 to 100 m for an entry velocity of 20 kms and stagnation pressures ranging from 1 to 100 atm; (ii) the influence of shape and departure of heating environment predictions from those for a simple spherical geometry; (iii) assessment of thermal response models for silica subject to intense radiation; and (iv) results for porosity-driven gross fragmentation of meteors, idealized as a collection of smaller objects. Lessons learned from these simulations will be used to help understand the Chelyabinsk meteor entry up to its first point of fragmentation.

Near-Earth Asteroids↗
DOE OSTI2019

Influence of Viscosity on Dynamic Magnetization of Thermally Blocked Iron Oxide Nanoparticles Characterized by a Sensitive AC Magnetometer

In this work, we show that the viscosity of carrier liquid affects the dynamic magnetization of thermally blocked multi-core iron oxide nanoparticles. The core size of the nanoparticles was determined from the magnetization curve measured by a specially developed high-T{sub c} SQUID magnetometer and calculated to be 11.7 nm. Using an AC magnetometer developed based on induction coils, the dynamic magnetization of the multi-core iron oxide nanoparticle solution was measured from 3 Hz to 10.48 kHz. Later, we reconstructed of the hydrodynamic size distribution of the particles by assuming a log-normal distribution of particle size in an AC susceptibility model by Shliomis and Stepanov, which accounts for anisotropic directions of the easy axes of magnetic nanoparticles with respect to the excitation field direction. The reconstructed hydrodynamic sizes showed an average diameter of 130 nm and agreed with the size determined by dynamic light scattering method. In the case of increasing viscosity of the carrier liquids from 0.89 to 8.11 mPa s, the dynamic magnetization peaks of the imaginary component have shifted to a lower frequency region. We showed that the harmonics ratio and phase delay upon the magnetic field excitation at 30 Hz could also be used to determine the viscosity of carrier liquid independently.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
NASA NTRS2015

Physics-Based Modeling of Meteor Entry and Breakup

A new research effort at NASA Ames Research Center has been initiated in Planetary Defense, which integrates the disciplines of planetary science, atmospheric entry physics, and physics-based risk assessment. This paper describes work within the new program and is focused on meteor entry and breakup. Over the last six decades significant effort was expended in the US and in Europe to understand meteor entry including ablation, fragmentation and airburst (if any) for various types of meteors ranging from stony to iron spectral types. These efforts have produced primarily empirical mathematical models based on observations. Weaknesses of these models, apart from their empiricism, are reliance on idealized shapes (spheres, cylinders, etc.) and simplified models for thermal response of meteoritic materials to aerodynamic and radiative heating. Furthermore, the fragmentation and energy release of meteors (airburst) is poorly understood. On the other hand, flight of human-made atmospheric entry capsules is well understood. The capsules and their requisite heatshields are designed and margined to survive entry. However, the highest speed Earth entry for capsules is less than 13 km/s (Stardust). Furthermore, Earth entry capsules have never exceeded diameters of 5 m, nor have their peak aerothermal environments exceeded 0.3 atm and 1 kW/cm2. The aims of the current work are: (i) to define the aerothermal environments for objects with entry velocities from 13 to greater than 20 km/s; (ii) to explore various hypotheses of fragmentation and airburst of stony meteors in the near term; (iii) to explore the possibility of performing relevant ground-based tests to verify candidate hypotheses; and (iv) to quantify the energy released in airbursts. The results of the new simulations will be used to anchor said risk assessment analyses. With these aims in mind, state-of-the-art entry capsule design tools are being extended for meteor entries. We describe: (i) applications of current simulation tools to spherical geometries of diameters ranging from 1 to 100 m for an entry velocity of 20 km/s and stagnation pressures ranging from 1 to 100 atm; (ii) the influence of shape and departure of heating environment predictions from those for a simple spherical geometry; (iii) assessment of thermal response models for silica subject to intense radiation; and (iv) results for porosity-driven gross fragmentation of meteors, idealized as a collection of smaller objects. Lessons learned from these simulations will be used to help understand the Chelyabinsk meteor entry up to its first point of fragmentation.

Aerothermodynamics↗
NASA NTRS2015

Physics-Based Modeling of Meteor Entry and Breakup

A new research effort at NASA Ames Research Center has been initiated in Planetary Defense, which integrates the disciplines of planetary science, atmospheric entry physics, and physics-based risk assessment. This paper describes work within the new program and is focused on meteor entry and breakup. Over the last six decades significant effort was expended in the US and in Europe to understand meteor entry including ablation, fragmentation and airburst (if any) for various types of meteors ranging from stony to iron spectral types. These efforts have produced primarily empirical mathematical models based on observations. Weaknesses of these models, apart from their empiricism, are reliance on idealized shapes (spheres, cylinders, etc.) and simplified models for thermal response of meteoritic materials to aerodynamic and radiative heating. Furthermore, the fragmentation and energy release of meteors (airburst) is poorly understood. On the other hand, flight of human-made atmospheric entry capsules is well understood. The capsules and their requisite heat shields are designed and margined to survive entry. However, the highest speed Earth entry for capsules is 13 kms (Stardust). Furthermore, Earth entry capsules have never exceeded diameters of 5 m, nor have their peak aerothermal environments exceeded 0.3 atm and 1 kWcm2. The aims of the current work are: (i) to define the aerothermal environments for objects with entry velocities from 13 to 20 kms; (ii) to explore various hypotheses of fragmentation and airburst of stony meteors in the near term; (iii) to explore the possibility of performing relevant ground-based tests to verify candidate hypotheses; and (iv) to quantify the energy released in airbursts. The results of the new simulations will be used to anchor said risk assessment analyses.With these aims in mind, state-of-the-art entry capsule design tools are being extended for meteor entries. We describe: (i) applications of current simulation tools to spherical geometries of diameters ranging from 1 to 100 m for an entry velocity of 20 kms and stagnation pressures ranging from 1 to 100 atm; (ii) the influence of shape and departure of heating environment predictions from those for a simple spherical geometry; (iii) assessment of thermal response models for silica subject to intense radiation; and (iv) results for porosity-driven gross fragmentation of meteors, idealized as a collection of smaller objects. Lessons learned from these simulations will be used to help understand the Chelyabinsk meteor entry up to its first point of fragmentation.

Atmospheric Entry↗
NASA NTRS2005

3-D GRMHD Simulations of Disk-Jet Coupling and Associated Variabilities and Emission

We have performed the fully three-dimensional general relativistic magnetohydrodynamic (GRMHD) simulation of jet formation from a thin accretion disk around a Schwarzschild black hole with a free-falling corona. The initial simulation results show that a bipolar jet is created as shown by previous two-dimensional axisymmetric simulations with mirror symmetry at the equator. The 3-D simulation ran over one hundred light-crossing time units which is considerably longer than the previous simulations. We show that the jet is initially formed as predicted due in part to magnetic pressure from the twisting the initially uniform magnetic field and from gas pressure associated with shock formation in the region around r = 3 r_S. At later times, the accretion disk becomes thick and the jet fades resulting in a wind that is ejected from the surface of the thickened (torus-like) disk. It should be noted that no streaming matter from a donor is included at the outer boundary in the simulation (an isolated black hole not binary black hole). The wind flows outwards with a wider angle than the initial jet. The widening of the jet is consistent with the outward moving torsional Alfven waves (TAWs). This evolution of disk-jet coupling suggests that the jet fades with a thickened accretion disk due to the lack of streaming material from an accompanying star. We will report initial results of emission calculated based on simulations with Kerr metric using a new ray-tracing method developed by S. Feurst and K. Wu. Images include free-free emission, absorption, and electron scattering. Fluorescent iron line emission and its variabilities from black holes will also be calculated based on simulation results.

Nishikawa, K. I.↗
DOE OSTI2013

Cyclic voltammetric study of Co-Ni-Fe alloys electrodeposition in sulfate medium

Electrochemical technique has been used to study the electrodeposition of cobalt, nickel, iron and Co-Ni-Fe alloy on indium tin oxide (ITO) coated glass substrate. To obtain the nucleation mechanism, cyclic voltammetry is used to characterize the Co-Ni-Fe system. The scanning rate effect on the deposition process was investigated. Deposition of single metal occurs at potential values more positive than that estimated stability potential. Based on the cyclic voltammetry results, the electrodeposition of cobalt, nickel, iron and Co-Ni-Fe alloy clearly show that the process of diffusion occurs is controlled by the typical nucleation mechanism.

36 MATERIALS SCIENCE↗
DOE OSTI2012

Mesoporous iron–manganese oxides for sulphur mustard and soman degradation

Graphical abstract: Display Omitted Highlights: ► New nanodispersive materials based on Fe and Mn oxides for degradations of warfare agents. ► The best activities for the degradation of sulphur mustard (97.9% in 64 min) and soman (97.9% in 64 min). ► One pot synthesis with friendly transformed to industrial conditions. -- Abstract: Substituted iron(III)–manganese(III, IV) oxides, ammonio-jarosite and birnessite, were prepared by a homogeneous hydrolysis of potassium permanganate and iron(III) sulphate with 2-chloroacetamide and urea, respectively. Synthesised oxides were characterised using Brunauer–Emmett–Teller (BET) surface area and Barrett–Joiner–Halenda porosity (BJH), X-ray diffraction (XRD), infrared spectroscopy (IR), Raman spectroscopy and scanning electron microscopy (SEM). The oxides were taken for an experimental evaluation of their reactivity against sulphur mustard (HD) and soman (GD). When ammonio-jarosite formation is suppressed by adding urea to the reaction mixture, the reaction products are mixtures of goethite, schwertmannite and ferrihydrite, and their degradation activity against soman considerably increases. The best activities for the degradation of sulphur mustard (97.9% in 64 min) and soman (97.9% in 64 min) were observed for FeMn{sub 7}5 with 32.6 wt.% Fe (36.8 wt.% Mn) and FeMn{sub 3}7U with 60.8 wt.% Fe (10.1 wt.% Mn) samples, respectively.

36 MATERIALS SCIENCE↗
DOE OSTI2017

TA [B] Predicting Microstructure-Creep Resistance Correlation in High Temperature Alloys over Multiple Time Scales

DoE-NETL partnered with Purdue University to predict the creep and associated microstructure evolution of tungsten-based refractory alloys. Researchers use grain boundary (GB) diagrams, a new concept, to establish time-dependent creep resistance and associated microstructure evolution of grain boundaries/intergranular films GB/IGF controlled creep as a function of load, environment, and temperature. The goal was to conduct a systematic study that includes the development of a theoretical framework, multiscale modeling, and experimental validation using W-based body-centered-cubic alloys, doped/alloyed with one or two of the following elements: nickel, palladium, cobalt, iron, and copper—typical refractory alloys. Prior work has already established and validated a basic theory for W-based binary and ternary alloys; the study conducted under this project extended this proven work. Based on interface diagrams phase field models were developed to predict long term microstructural evolution. In order to validate the models nanoindentation creep data was used to elucidate the role played by the interface properties in predicting long term creep strength and microstructure evolution.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2016

CHARGE SPECTRUM OF HEAVY AND SUPERHEAVY COMPONENTS OF GALACTIC COSMIC RAYS: RESULTS OF THE OLIMPIYA EXPERIMENT

The aim of the OLIMPIYA experiment is to search for and identify traces of heavy and superheavy nuclei of galactic cosmic rays (GCR) in olivine crystals from stony–iron meteorites serving as nuclear track detectors. The method is based on layer-by-layer grinding and etching of particle tracks in these crystals. Unlike the techniques of other authors, this annealing-free method uses two parameters: the etching rate along the track ( V {sub etch}) and the total track length ( L ), to identify charge Z of a projectile. A series of irradiations with different swift heavy ions at the accelerator facilities of GSI (Darmstadt) and IMP (Lanzhou) were performed in order to determine and calibrate the dependence of projectile charge on V {sub etch} and L . To date, one of the most essential results of the experiment is the obtained charge spectrum of GCR nuclei within the range of Z > 40, based on about 11.6 thousand processed tracks. As the result of data processing, 384 nuclei with charges Z ≥ 75 have been identified, including 10 nuclei identified as actinides (90 < Z < 103). Three tracks were identified to be produced by nuclei with charges 113 < Z < 129. Such nuclei may be part of the Island of Stability of transfermium elements.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2016

Suzaku observations of moderately obscured (Compton-thin) active galactic nuclei selected by Swift/BAT hard X-ray survey

We report the results obtained by a systematic, broadband (0.5–150 keV) X-ray spectral analysis of moderately obscured (Compton-thin, 22⩽logN{sub H}<24) active galactic nuclei (AGNs) observed with Suzaku and Swift/Burst Alert Telescope (BAT). Our sample consists of 45 local AGNs at z<0.1 with logL{sub 14−195keV}>42 detected in the Swift/BAT 70-month survey, whose Suzaku archival data are available as of 2015 December. All spectra are uniformly fit with a baseline model composed of an absorbed cutoff power-law component, reflected emission accompanied by a narrow fluorescent iron-Kα line from cold matter (torus), and scattered emission. The main results based on the above analysis are as follows. (1) The photon index is correlated with Eddington ratio, but not with luminosity or black hole mass. (2) The ratio of the luminosity of the iron-Kα line to the X-ray luminosity an indicator of the covering fraction of the torus, shows significant anticorrelation with luminosity. (3) The averaged reflection strength derived from stacked spectra above 14 keV is larger in less luminous (logL{sub 10−50keV}⩽43.3, R=1.04{sub −0.19}{sup +0.17}) or highly obscured (logN{sub H}>23, R=1.03{sub −0.17}{sup +0.15}) AGNs than in more luminous (logL{sub 10−50keV}>43.3, R=0.46{sub −0.09}{sup +0.08}) or lightly obscured (logN{sub H}⩽23, R=0.59{sub −0.10}{sup +0.09}) objects. (4) The ratio of the luminosity of the [O IV] 25.89 μm line to the X-ray luminosity is significantly smaller in AGNs with lower soft X-ray scattering fractions, suggesting that the former luminosity underestimates the intrinsic power of an AGN buried in a torus of small opening angle.

79 ASTRONOMY AND ASTROPHYSICS↗
NASA NTRS1993

Development of an iron nitrate resistant injector valve for the Space Shuttle orbiter primary thruster

Design of a direct-acting valve (DAV) for a primary thruster which is fully interchangeable with a thruster equipped with pilot-operated valves is described. The DAV is based on a bellows to isolate propellants form the actuator for maximum resistance to iron nitrate and other contamination and to select optimum materials for the actuator. It provides improved seal performance under all operating conditions and insensitivity to pressure transients. As compared with the existing pilot-operated valve, the DAV design is much simpler, consists of fewer parts, and will be lower in cost.

Wichmann, Horst↗
DOE OSTI2014

Long-term oxidation of candidate cast iron and stainless steel exhaust system alloys from 650 to 800 °C in air with water vapor

Here, the oxidation behavior of SiMo cast iron, Ni-resist D 5 S cast iron, cast chromia-forming austenitic stainless steels of varying Cr/Ni content based on CF8C plus, HK, and HP, and a developmental cast alumina-forming austenitic (AFA) stainless steel of interest for diesel exhaust system components were studied for up to 5000 h at 650-800 °C in air with 10% H 2 O. At 650 °C, the Ni-resist D5S exhibited moderately better oxidation resistance than did the SiMo cast iron. However, the D5S suffered from oxide scale spallation issues at 700 °C and higher, whereas the oxide scales formed on SiMo cast iron remained adherent from 700-800 °C despite oxide scales hundreds of microns thick. The oxidation of the SiMo cast iron exhibited unusual temperature dependence, with periods of slower oxidation kinetics at 750-800 °C compared to 650-700 °C due to continuous silica-rich scale formation at the higher temperatures. The oxidation of the cast chromia-forming austenitics trended with the level of Cr and Ni additions, with small mass losses consistent with Cr oxy-hydroxide volatilization processes for the higher 25Cr/25-35Ni HK and HP type alloys, and transition to rapid Fe-base oxide formation and scale spallation in the lower 19Cr/12Ni CF8C plus type alloy. In contrast, small positive mass changes consistent with protective alumina scale formation were observed for the cast AFA alloy under all conditions studied. Implications of these findings for diesel exhaust system components are discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Activating magnetite ores for aqueous ironmaking at high current densities

Low-temperature electrochemical cells reducing iron oxides to metal in alkaline electrolytes can support fully electrified steelmaking processes. Previous studies on these cells have primarily focused on high-surface-area hematite, Fe 2 O 3 , reactants whereas attempts to reduce suspensions of magnetite, Fe 3 O 4 —one of the two feedstocks for existing ironmaking reactors—have generally been limited to low rates of reaction (<30 mA cm −2 ). Here, in this study, we control the crystalline domain size of Fe 2 O 3 and Fe 3 O 4 particles in 10 M NaOH electrolytes to study how the nanoscale morphology of oxides controls the rate of electrochemical ironmaking. Rotating-ring disk electrode measurements of Fe 2+ , in situ Raman spectroscopy of the electrode surface, and ex situ electron microscopy were consistent with a hypothesized passivation process at Fe 3 O 4 surfaces that may prevent the continuous formation of soluble intermediates. Sufficiently small (<100 nm diameter) oxide particles yielded Fe partial current densities >160 mA cm −2 , a fivefold increase relative to previously reported rates for Fe 3 O 4 suspensions and comparable to active Fe 2 O 3 . Electron microscopy revealed that electrodeposited films were composed of micron-scale crystalline Fe domains with a porous film of Fe 3 O 4 nanoparticles and supports a model where Fe is grown primarily from soluble Fe 2+ intermediates. Based on these insights, inactive blast-furnace-grade iron-oxides were transformed into high surface area nanoparticles (1.6 to 229.2 m 2 g −1 ) via reprecipitation, leading to a ninefold enhancement in faradaic efficiency and an Fe partial current density of 120 mA cm −2 . When integrated with chlor-iron cells producing reagents for reprecipitation, this approach could lead to a cost-competitive process for electrochemical ironmaking from industrially relevant feedstocks.

TEM↗