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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 1,513 records · Page 84
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Uranium corrosion characterization by handheld laser-induced breakdown spectroscopy

In this study, a commercial-off-the-shelf handheld laser-induced breakdown spectroscopy system was modified, calibrated and tested for discrimination between uranium oxide and uranium hydride when assessing uranium corrosion products. Operating parameters, system modifications, and onboard data analysis were developed to accomplish the analytical task. This work represents the first laser-induced breakdown spectroscopy analysis of bulk uranium hydride, a pyrophoric material, within an inert glovebox. Finally, the work shown here illustrates a rapid identification technique for uranium corrosion types from pure UO 2 or U 3 O 8 to pure UH 3 .

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2017

Assessment of Corrosion Resistance of Candidate Alloys for Accident Tolerant Fuel Cladding under Reactor Conditions

The environment of a light water reactor (LWR) core is a combination of high temperatures, high pressures, high neutron and gamma fluxes, mechanical stresses and chemical aggressive coolants. All of these factors combined can induce changes in the microstructure of the fuel and cladding that are very difficult to predict in a systematic fashion [1] and are major challenge for the safety and life extension of current reactors. Throughout reactor transients and accidents, the cladding may experience deterioration caused by a temperature increase, oxidation embrittlement [1], [2], or mechanical interaction with the fuel caused by stress [3]. These events may lead to cracking or rupture of the cladding, causing the release of fission products into the coolant. Such events have been observed at the Three Mile Island and Fukushima accidents. To avoid such occurrences in LWRs, the accident tolerant fuels (ATF) program was initiated to focus on the replacement of zirconium-based alloys with materials that exhibit slower steam oxidation kinetics. This project focuses on several iron-based alloys such as T91, APMT, MA956, experimental Fe-Cr alloys and one experimental nanofeatured alloy (NFA). Experiments have been conducted in both PWR primary water at 320°C and BWR normal water chemistry at 288°C, spanning a large range in electrochemical corrosion potential (ECP). Samples were exposed to either proton irradiation (University of Michigan) or electron irradiation (Notre Dame Radiation Laboratory) to independently assess the roles of displacement damage or radiolysis on the corrosion rate, oxide thickness, morphology, structure and resistivity. Post-irradiation characterization of various regions of the electronirradiated samples was completed by means of microscopy (Notre Dame Integrated Imaging Facility) and spectroscopy (Notre Dame Materials Characterization Facility) techniques to provide high resolution information regarding the oxide layer present on the surface of the material.

Grdanovska, Slavica↗
DOE OSTI2021

Unraveling the Formation Mechanism of a Hybrid Zr-Based Chemical Conversion Coating with Organic and Copper Compounds for Corrosion Inhibition

Environmental-friendly chromate-free, zirconium (Zr)-based conversion coating is a promising green technology for corrosion protection. Additives in the surface treatment provides critical functionalities and performance improvements; however, mechanistic understanding as of how the additives influence the coatings remains unclear. In this study, a new organic-inorganic hybrid Zrbased conversion coating which combines copper (Cu) compounds and polyamidoamine (PAMAM), taking advantages of a complementary nature of organic and inorganic additives. Here, a multimodal approach combining electron and X-ray characterization is applied to study the interaction of Cu 2+ and PAMAM and the resulting impacts on the coating formation. Adding PAMAM changed the surface morphology, thickness, distribution of Cu in the cluster and void formation of the coatings. High PAMAM (100-200 pm) leads to little conversion coating formation, and low PAMAM (0-25 ppm) shows voids formation under the coatings. Moreover, PAMAM incorporates in the coating in a form of PAMAM-Cu complex with a higher concentration towards the surface, provides an organic layer at the surface of the coating. X-ray absorption near-edge structure (XANES) spectroscopy shows a difference between the conventional and hybrid coating treatments in an alkaline solution to simulate the E-coat process, suggesting the contribution of PAMAM in the enhanced chemical stability in an alkaline environment. Therefore, an intermediate range of addition of PAMAM (50 ppm) is optimal to 1) avoid excessive voids formation, 2) promote some Cu cluster formation and thus enhancing the Zr-based coating formation and 3) incorporate organic components into the coating to improve the adhesion of the subsequent coatings. Overall, this work furthers our knowledge on the formation mechanism of an effective and environmentally friendly hybrid conversion coating for corrosion inhibition, demonstrating a critical processing-structureproperty relationship. This study will benefit future development of green and effective surface treatment technology.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2018

Turning a native or corroded Mg alloy surface into an anti-corrosion coating in excited CO 2

Despite their energy-efficient merits as promising light-weight structural materials, magnesium (Mg) based alloys suffer from inadequate corrosion resistance. One primary reason is that the native surface film on Mg formed in air mainly consists of Mg(OH) 2 and MgO, which is porous and unprotective, especially in humid environments. Here, we demonstrate an environmentally benign method to grow a protective film on the surface of Mg/Mg alloy samples at room temperature, via a direct reaction of already-existing surface film with excited CO 2 . Moreover, for samples that have been corroded obviously on surface, the corrosion products can be converted directly to create a new protective surface. Mechanical tests show that compared with untreated samples, the protective layer can elevate the yield stress, suppress plastic instability and prolong compressive strains without peeling off from the metal surface. This environmentally friendly surface treatment method is promising to protect Mg alloys, including those already-corroded on the surface.

36 MATERIALS SCIENCE↗
DOE OSTI2018

A comparative review of the aqueous corrosion of glasses, crystalline ceramics, and metals

All materials can suffer from environmental degradation; the rate and extent of degradation depend on the details of the material composition and structure as well as the environment. The corrosion of silicate glasses, crystalline ceramics, and metals, particularly as related to nuclear waste forms, has received a lot of attention. The corrosion phenomena and mechanisms of these materials are different, but also have many similarities. Furthermore, this review compares and contrasts the mechanisms of environmental degradation of glass, crystalline ceramics, and metals, with the goal of identifying commonalities that can seed synergistic activities and advance the current knowledge in each area.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Revealing the growth kinetics of atmospheric corrosion pitting in aluminum via in situ microtomography

Abstract Understanding the mechanistic relationship between the environment, microstructure, and local kinetics of atmospheric corrosion damage remains a central challenge. To address this challenge, this study used laboratory-based X-ray tomography to directly observe attack in-operando over an extended period, enabling insights into the evolving growth kinetics and morphology of individual pits over months of exposure. Damage progression associated with nine pits in a 99.9% pure aluminum wire exposed to chloride salts in humid air was characterized. Most pits grew at a nominally linear rate up until pit death, which occurred within 12–24 h of nucleation. Exceptions to this were observed, with three pits exhibiting bimodal growth kinetics and growing for 40 or more hours. This was explained by secondary droplets that formed near the pits, increasing the cathode area. A corrosion-driven drying mechanism likely contributed to pit death in both cases. Pits first grew into the material followed by lateral expansion.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Review of corrosion interactions between different materials relevant to disposal of high-level nuclear waste

Abstract This review covers the corrosion interactions between different materials that are relevant to the disposal of high-level nuclear waste, in particular the waste forms and containers. The materials of interest are borosilicate glass, crystalline ceramics, metal alloys, and any corrosion products that might form. The available data show that these interactions depend on the structure, chemistry, thermodynamic history, and proximity of the materials in contact, as well as the environmental attributes, such as temperature, solution chemistry, and radiation. Several key mechanisms that govern these interactions are highlighted. Scientific gaps and open questions are summarized and discussed.

Materials Science↗
DOE OSTI2021

Development of a numerical model for simulating stress corrosion cracking in spent nuclear fuel canisters

Abstract Prediction and detection of the chloride-induced stress corrosion cracking (CISCC) in Type 304 stainless steel spent nuclear fuel canisters are vital for the lifetime extension of dry storage canisters. This paper conducts a critical review that focuses on the numerical modeling and simulation on the research progress of the CISCC. The numerical models emphasizing the residual stress, susceptible microstructure, and corrosive environment are summarized individually. Meanwhile, the simulation studies on the role of hydrogen-assisted cracking are reviewed. Finally, a multi-physical numerical model, which combines the different fields is proposed based on our recent investigation.

Materials Science↗
DOE OSTI2022

Insights on the corrosion thermodynamics of chromium in molten LiF-NaF-KF eutectic salts

The thermodynamic stability of chromium in the Cr 0 , Cr 2+ , and Cr 3+ oxidation states considering various F - ion coordination compounds was investigated in molten LiF–NaF-KF (FLiNaK) eutectic salt. Potential fluoride ion activity (F - and CrF 3 - ) diagrams were constructed to predict the most stable Cr oxidation states as a function of anion activity, solvation state of chromium ions and potential at 600 °C. The Gibbs free energies of these compounds were estimated by utilizing a combined cyclic voltammetry – Nernst theory analysis approach in FLiNaK salt. To verify the constructed diagrams, X-ray diffraction was utilized after exposure of Cr at various applied potentials to determine whether compounds detected in solidified FLiNaK salts agreed with thermodynamic calculations. This work aims to identify key thermodynamic factors that are significant to chromium corrosion for molten salt nuclear reactor applications. The F - stability region spans the entire region where spontaneous corrosion of Cr occurs. Cr may be oxidized to Cr 2+ and Cr 3+ in the presence HF (due to moisture as an impurity) spontaneously except some conditions of p 1/2 H 2 /a HF etc. This situation is not changed qualitatively for various states of solvation between oxidized Cr solute in F - solvent and this aspect is substantially similar for the two cases (pair 1: Cr 0 /CrF 3 - / CrF 6 3- ; pair 2: Cr 0 /CrF 4 2- /CrF 5 2- ) considered in this work.

36 MATERIALS SCIENCE↗
DOE OSTI2023

The evolution of pit morphology and growth kinetics in aluminum during atmospheric corrosion

Abstract Assessing the lifetimes of alloys in humid, corrosive environments requires growth kinetic information regarding individual instances of damage, e.g. pit growth rates. Corrosion rates measured at the continuum scale using mass change convolute the rate of pit nucleation and growth, providing limited information on local kinetics. The current study used in-situ X-ray computed tomography to measure growth rates of individual pits in aluminum over 100 h of exposure in a humid, chloride environment. While pits grew at relatively constant rates over the first hours after nucleation, significant growth-rate nonlinearities subsequently occurred. These were linked to both droplet spreading, which altered the cathode size, and changes in the mode of pit growth. Pit morphology appeared to influence the dominant growth mode and the duration of pit growth. Post-mortem serial sectioning revealed pits preferentially attacked grain-boundary triple junctions and dislocation boundaries.

Noell, Philip J. (ORCID:0000000346998999)↗
DOE OSTI2021

Corrosion of lithium metal anodes during calendar ageing and its microscopic origins

Rechargeable lithium (Li) metal batteries must have long cycle life and calendar life (retention of capacity during storage at open circuit). Particular emphasis has been placed on prolonging the cycle life of Li metal anodes, but calendar ageing is less understood. Here, we show that Li metal loses at least 2–3% of its capacity after only 24 hours of ageing, regardless of the electrolyte chemistry. These losses of capacity during calendar ageing also shorten the cycle life of Li metal batteries. Cryogenic transmission electron microscopy shows that chemical corrosion of Li and the continuous growth of the solid electrolyte interphase—a passivation film on Li—cause the loss of capacity. Electrolytes with long cycle life do not necessarily form a solid electrolyte interphase with more resistance to chemical corrosion, so functional electrolytes must simultaneously minimize the rate of solid electrolyte interphase growth and the surface area of electrodeposited Li metal.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Corrosion and Thermal Stability of CrMnFeNi High Entropy Alloy in Molten FLiBe Salt

The corrosion behavior of the FCC Cr 18 Mn 27 Fe 27.5 Ni 27.5 high entropy alloy (HEA) after exposure to molten FLiBe salt at 700 °C for 1000 hours, has been investigated. Results show that the HEA lost a higher mass compared to the reference 316 H stainless steel due to the dissolution of Mn into the molten salt. The loss of Mn from the alloy appeared to discourage the dissolution of Cr in the molten fluoride salts which is widely recognized as the mechanism of corrosion degradation. Thermal exposure at 700 °C for 1000 hours also led to the precipitation of an additional BCC phase Cr 67 Fe 13 Mn 18.5 Ni 1.5 , which was confirmed by CALPHAD predictions.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Studying localized corrosion using liquid cell transmission electron microscopy

Using liquid cell transmission electron microscopy (LCTEM), localized corrosion of Cu and Al thin films immersed in aqueous NaCl solutions was studied. We demonstrate that potentiostatic control can be used to initiate pitting and that local compositional changes, due to focused ion beam implantation of Au + ions, can modify the corrosion susceptibility of Al films. Likewise, a discussion on strategies to control the onset of pitting is also presented.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Frequency-domain hot-wire sensor and 3D model for thermal conductivity measurements of reactive and corrosive materials at high temperatures

High temperature solids and liquids are becoming increasingly important in next-generation energy and manufacturing systems that seek higher efficiencies and lower emissions. Accurate measurements of thermal conductivity at high temperatures are required for the modeling and design of these systems, but commonly employed time-domain measurements can have errors from convection, corrosion, and ambient temperature fluctuations. Here, we describe the development of a frequency-domain hot-wire technique capable of accurately measuring the thermal conductivity of solid and molten compounds from room temperature up to 800 °C. Therefore, by operating in the frequency-domain, we can lock into the harmonic thermal response of the material and reject the influence of ambient temperature fluctuations, and we can keep the probed volume below 1 µl to minimize convection. The design of the microfabricated hot-wire sensor, electrical systems, and insulating wire coating to protect against corrosion is covered in detail. Furthermore, we discuss the development of a full three-dimensional multilayer thermal model that accounts for both radial conduction into the sample and axial conduction along the wire and the effect of wire coatings. The 3D, multilayer model facilitates the measurement of small sample volumes important for material development. A sensitivity analysis and an error propagation calculation of the frequency-domain thermal model are performed to demonstrate what factors are most important for thermal conductivity measurements. Finally, we show thermal conductivity measurements including model data fitting on gas (argon), solid (sulfur), and molten substances over a range of temperatures.

47 OTHER INSTRUMENTATION↗
DOE OSTI2025

A new method for measuring refractory corrosion of ceramics in glass

Abstract Nuclear waste glass vitrification furnaces are lined with refractory ceramic blocks to contain the molten glass. The refractory liner is susceptible to corrosion and has a finite service lifetime. For this reason, predicting the refractory corrosion in contact with molten glass is integral to estimating melter service lifetime. Standardized laboratory tests varying time and temperature are commonly performed to estimate refractory material loss as a function of glass composition. These data are time and resource‐intensive to collect and are susceptible to considerable measurement error. In order to accelerate glass formulation and design for nuclear waste vitrification, methods are needed to increase laboratory‐scale throughput while maintaining data quality. In this work, a method to remove the residual glass from a corroded coupon using hydrofluoric acid is presented that accelerates the throughput of sample analysis while simultaneously facilitating more accurate measurements.

Amoroso, Jake W. [Savannah River National Laborato↗
DOE OSTI2020

First-Principles Modeling of the Repassivation of Corrosion Resistant Alloys: Part II. Surface Adsorption Isotherms for Alloys and the Chloride Susceptibility Index

Quantitatively predicting the corrosion resistance of alloys is vital to the design and application of the next generation of superior corrosion resistant alloys (CRAs). Here, the Chloride Susceptibility Index (CSI), a scientifically based quantitative descriptor for repassivation tendency of CRAs, is proposed as a metric constructed through combining atomistically resolved information regarding adsorption and alloy surface composition with environmental conditions such as applied potential, temperature, pH, and Cl – concentration. Using this method, the response of CRAs to relevant environments can be predicted. CSI is determined by: (1) estimation of thermoequilibrium surface coverages of O and Cl by a Langmuir isotherm model using adsorption energies of different species (O, Cl, OH, H 2 O) obtained from DFT. (2) determination of CSI by integrating Cl surface coverage over a realistic window of applied potentials, thereby incorporating the effect of Cl surface coverage and electrochemical environment simultaneously. A series of Ni-Cr-X alloys was used as an example to develop and validate the method through studying the effect of different alloy solutes X on chloride resistance. Here, the trends and relations predicted by CSI are in qualitative agreements with experimental observations. Moreover, a quantitative correlation is found between CSI and the repassivation potential.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Morphological Evolution and Dealloying During Corrosion of Ni20Cr (wt.%) in Molten FLiNaK Salts

The dealloying corrosion behavior of the FCC Ni20Cr (wt%) in molten LiF-NaF-KF (FLiNaK) salts at 600 °C under varying applied potentials was investigated. Using in-operando electrochemical techniques and a multi-modal suite of characterization methods, we connect electrochemical potential, thermodynamic stability, and electro-dissolution kinetics to the corrosion morphologies. Notably, under certain potential regimes, a micron-scale bicontinuous structure, characterized by a network of interconnected pores and ligaments riched with the composition of the more noble (MN) element, becomes prominent. At other potentials both MN and less noble (LN) elements dealloy but at different rates. The dealloying process consists of lattice and grain boundary diffusion of Cr to the metal/salt interface, interphase Cr oxidation, accompanied by surface diffusion of Ni to form interconnected ligaments. At higher potentials, the bicontinuous porous structure undergoes further surface coarsening. Concurrently, Cr(II), Cr(III), and Ni(II) begin to dissolve, with the dissolution of Ni occurring at a significantly slower rate. When solid-state transport of Cr is exceeded by the interfacial rates, dealloying depths are limited.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2019

Effect of Metallic Li on the Corrosion Behavior of Inconel 625 in Molten LiCl-Li 2 O-Li

The corrosion behavior of Inconel 625 in molten LiCl solutions maintained at 650°C and containing various quantities of Li 2 O and metallic Li was studied for possible application in the electroreduction of used oxide-based nuclear fuel. This study focusses on the morphological and elemental changes on the surface of the samples with an emphasis on cross-sectional analyses conducted using focused ion beam microscopy. In the absence of metallic Li, a stable oxide film is formed that limits the corrosion of the base material to 0.07mm/year. However, in the presence of metallic Li, the formation of this film is impeded, resulting in dealloying of the base material and the formation of a highly porous microstructure composed primarily of Ni.

36 MATERIALS SCIENCE↗