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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 163 records · Page 9

Cryogenic absolute radiometers as laboratory irradiance standards, remote sensing detectors, and pyroheliometers

The dramatic improvement in heat diffusivity of pure Cu at liquid-He temperatures makes possible very important advances in the absolute accuracy, reproducibility, sensitivity, and time constant of cryogenic electrical substitution radiometers (ESRs), relative to conventional ESRs. The design and characterization of a table-top cryogenic ESR now available for detector calibration work to the 0.01-percent level of absolute accuracy under laser illumination is discussed. A sensitive cryogenic ESR recently delivered to the NIST for radiometric calibrations of black bodies is also described, along with the design and testing of a very fast cryogenic ESR developed for NASA remote-sensing studies of the earth's radiation budget.

Foukal, Peter V.↗

Infrared Spectroscopy as a Chemical Fingerprinting Tool

Infrared (IR) spectroscopy is a powerful analytical tool in the chemical fingerprinting of materials. Any sample material that will interact with infrared light produces a spectrum and, although normally associated with organic materials, inorganic compounds may also be infrared active. The technique is rapid, reproducible and usually non-invasive to the sample. That it is non-invasive allows for additional characterization of the original material using other analytical techniques including thermal analysis and RAMAN spectroscopic techniques. With the appropriate accessories, the technique can be used to examine samples in liquid, solid or gas phase. Both aqueous and non-aqueous free-flowing solutions can be analyzed, as can viscous liquids such as heavy oils and greases. Solid samples of varying sizes and shapes may also be examined and with the addition of microscopic IR (microspectroscopy) capabilities, minute materials such as single fibers and threads may be analyzed. With the addition of appropriate software, microspectroscopy can be used for automated discrete point or compositional surface area mapping, with the latter providing a means to record changes in the chemical composition of a material surface over a defined area. Due to the ability to characterize gaseous samples, IR spectroscopy can also be coupled with thermal processes such as thermogravimetric (TG) analyses to provide both thermal and chemical data in a single run. In this configuration, solids (or liquids) heated in a TG analyzer undergo decomposition, with the evolving gases directed into the IR spectrometer. Thus, information is provided on the thermal properties of a material and the order in which its chemical constituents are broken down during incremental heating. Specific examples of these varied applications will be cited, with data interpretation and method limitations further discussed.

Huff, Timothy L.↗

Parameterizing Gravity Waves and Understanding Their Impacts on Venus' Upper Atmosphere

The complexity of Venus’ upper atmospheric circulation is still being investigated. Simulations of Venus’ upper atmosphere largely depend on the utility of Rayleigh Friction (RF) as a driver and necessary process to reproduce observations (i.e. temperature, density, nightglow emission). Currently, there are additional observations which provide more constraints to help characterize the driver(s) of the circulation. This work will largely focus on the impact parameterized gravity waves have on Venus’ upper atmosphere circulation within a three dimensional hydrodynamic model (Venus Thermospheric General Circulation Model).

Brecht, A. S.↗

Global Ocean Mass Change Derived From Atmospheric Reanalyses

Barystatic sea level change is a significant climate variable and a gauge for water exchanges between land, atmosphere, and ocean, with consequential relevance to stakeholders. The monitoring and attribution of globally averaged sea level variations represents substantial challenges to the climate community. Atmospheric reanalyses provide a level of monitoring for elements of the climate system that are in communication with the ocean, including the atmosphere, terrestrial land, and the surfaces of glaciated land. Global atmospheric reanalyses comprise model output that is statistically adjusted to available observations. Potentially, reanalyses offer a climatic context to observed changes in water mass distribution. Improvement in the representation of the water cycle and in water mass conservation have been stated goals of reanalysis projects. Here, we assess the capability of atmospheric reanalyses to represent variations in the global water budget from the perspective of ocean mass balance. The purpose of this work is to provide a detailed evaluation of current atmospheric reanalyses and their ability to reproduce spatial and temporal variations in atmospheric and terrestrial water storage. A second goal is to identify and characterize recent apparent trends in the water balance. We examine the ERA5, MERRA-2, and JRA-3Q reanalyses with a focus on the radio-occultation observing period from 2007 to the present. For terrestrial water storage we also compare with ERA5-Land, a surface reanalysis. The primary validation is from the NASA/DLR Gravity Recovery and Climate Experiment (GRACE) and its follow-on, GRACE-FO. The Atmospheric Infrared Sounder (AIRS) onboard NASA's Aqua satellite is also used for evaluation of the atmospheric moisture budget. Comparisons reveal strengths and weaknesses in the reanalyses of each component of the climate system. Reanalyses agree closely on atmospheric moisture storage trends, although mean values differ. Reanalyses show significant differences in land water storage. They also apply large corrections to the land water budget. Finally, reanalyses have differing abilities in representing the surface mass balance over glaciated land. Using the observed gravimetry record, changes in the underlying glaciated land ice are examined as a residual.

Richard Cullather↗

Assessment of impact damage of composite rocket motor cases

This contract reviewed the available literature on mechanisms of low velocity impact damage in filament wound rocket motor cases, MDE methods to quantify damage, critical coupon level test methods, manufacturing and material process variables and empirical and analytical modeling off impact damage. The critical design properties for rocket motor cases are biaxial hoop and axial tensile strength. Low velocity impact damage is insidious because it can create serious nonvisible damage at very low impact velocities. In thick rocket motor cases the prevalent low velocity impact damage is fiber fracture and matrix cracking adjacent to the front face. In contrast, low velocity loading of thin wall cylinders induces flexure, depending on span length and the flexure induces delamination and tensile cracking on the back face wall opposed to impact occurs due to flexural stresses imposed by impact loading. Important NDE methods for rocket motor cases are non-contacting methods that allow inspection from one side. Among these are vibrothermography, and pulse-echo methods based on acoustic-ultrasonic methods. High resolution techniques such as x-ray computed tomography appear to have merit for accurate geometrical characterization of local damage to support development of analytical models of micromechanics. The challenge of coupon level testing is to reproduce the biaxial stress state that the full scale article experiences, and to determine how to scale the composite structure to model full sized behavior. Biaxial tensile testing has been performed by uniaxially tensile loading internally pressurized cylinders. This is experimentally difficult due to gripping problems and pressure containment. Much prior work focused on uniaxial tensile testing of model filament wound cylinders. Interpretation of the results of some studies is complicated by the fact that the fabrication process did not duplicate full scale manufacturing. It is difficult to scale results from testing subscale cylinders since there are significant differences in out time of the resins relative to full scale cylinder fabrication, differences in hoop fiber tensioning and unsatisfactory coupon configurations. It appears that development of a new test method for subscale cylinders is merited. Damage tolerance may be improved by material optimization that uses fiber treatments and matrix modifications to control the fiber matrix interface bonding. It is difficult to develop process optimization in subscale cylinders without also modeling the longer out times resins experience in full scale testing. A major breakthrough in characterizing the effect of impact damage on residual strength, and understanding how to scale results of subscale evaluations, will be a sound micromechanical model that described progressive failure of the composite. Such models will utilize a three dimensional stress analysis due to the complex nature of low velocity impact stresses in thick composites. When these models are coupled with non-contact NDE methods that geometrically characterize the damage and acoustic methods that characterize the effective local elastic properties, accurate assessment of residual strength from impact damage may be possible. Directions for further development are suggested.

Paris, Henry G.↗

A Comparison of the SOCIT and DebriSat Experiments

This paper explores the differences between, and shares the lessons learned from, two hypervelocity impact experiments critical to the update of orbital debris environment models. The procedures and processes of the fourth Satellite Orbital Debris Characterization Impact Test (SOCIT) were analyzed and related to the ongoing DebriSat experiment. SOCIT was the first hypervelocity impact test designed specifically for satellites in Low Earth Orbit (LEO). It targeted a 1960's U.S. Navy satellite, from which data was obtained to update pre-existing NASA and DOD breakup models. DebriSat is a comprehensive update to these satellite breakup models- necessary since the material composition and design of satellites have evolved from the time of SOCIT. Specifically, DebriSat utilized carbon fiber, a composite not commonly used in satellites during the construction of the US Navy Transit satellite used in SOCIT. Although DebriSat is an ongoing activity, multiple points of difference are drawn between the two projects. Significantly, the hypervelocity tests were conducted with two distinct satellite models and test configurations, including projectile and chamber layout. While both hypervelocity tests utilized soft catch systems to minimize fragment damage to its post-impact shape, SOCIT only covered 65% of the projected area surrounding the satellite, whereas, DebriSat was completely surrounded cross-range and downrange by the foam panels to more completely collect fragments. Furthermore, utilizing lessons learned from SOCIT, DebriSat's post-impact processing varies in methodology (i.e., fragment collection, measurement, and characterization). For example, fragment sizes were manually determined during the SOCIT experiment, while DebriSat utilizes automated imaging systems for measuring fragments, maximizing repeatability while minimizing the potential for human error. In addition to exploring these variations in methodologies and processes, this paper also presents the challenges DebriSat has encountered thus far and how they were addressed. Accomplishing DebriSat's goal of collecting 90% of the debris, which constitutes well over 100,000 fragments, required addressing many challenges stemming from the very large number of fragments. One of these challenges arose in identifying the foam-embedded fragments. DebriSat addressed this by X-raying all of the panels once the loose debris were removed, and applying a detection algorithm developed in-house to automate the embedded fragment identification process. It is easy to see how the amount of data being compiled would be outstanding. Creating an efficient way to catalog each fragment, as well as archiving the data for reproducibility also posed a great challenge for DebriSat. Barcodes to label each fragment were introduced with the foresight that once the characterization process began, the datasheet for each fragment would have to be accessed again quickly and efficiently. The DebriSat experiment has benefited significantly by leveraging lessons learned from the SOCIT experiment along with the technological advancements that have occurred during the time between the experiments. The two experiments represent two ages of satellite technology and, together, demonstrate the continuous efforts to improve the experimental techniques for fragmentation debris characterization.

Ausay, Erick↗

Recommendations to standardize reporting, execution and interpretation of STEM/TEM measurements

In July of 2022, a National Science Foundation (NSF)- and US Department of Energy (DOE)-sponsored workshop was held on the topic of rigor and reproducibility (R&R) in thermal, heterogeneous catalysis. A report has been published entitled “Addressing Rigor and Reproducibility in Thermal, Heterogeneous Catalysis” as a result of the workshop [1]. This manuscript attempts to summarize one section of the report entitled Recommendations for catalyst characterization by transmission electron microscopy.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Effect of Thermodynamic and Environmental Factors on Crystallization of DNA‐Origami Superlattices

The directed self‐assembly of nanoscale materials into ordered superlattices presents a powerful strategy for creating next‐generation materials with programmable mechanical, optical, and photonic properties. Deoxyribonucleic acid (DNA) origami has emerged as a versatile scaffold for encoding nanoscale geometry and guiding the crystallization of complex 3D architectures. However, a systematic understanding of the parameters that govern the efficiency and quality of superlattice formation remains limited. In this study, we utilize octahedral DNA nanoscale frames as a model system to investigate the relative influence of key factors, including buffer composition, ionic strength, frame concentration, and thermal annealing protocols, on the size, order, and reproducibility of the resulting superlattices. Our findings provide a quantitative framework to rationally optimize DNA‐based assembly pathways. Structural characterization via small‐angle x‐ray scattering (SAXS), scanning electron microscopy (SEM), and optical microscopy validates the quality and fidelity of the assembled lattices. Moreover, by templating these DNA frameworks into inorganic replicas, we establish general design principles that extend beyond biomolecular systems, providing a foundation for the synthesis of programmable materials in broader nanofabrication contexts.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

Solution Structure and Scaling Laws of Cylindrical and Tapered Bottlebrush Polymers

Bottlebrush polymers are a unique class of macromolecular architectures with a plethora of potential industrial and pharmaceutical applications that critically depend on the bottlebrush shape and dimensions. Here, a systematic series of 12 cylindrical and 12 cone-shaped (tapered) bottlebrush polymers with poly(tert-butyl acrylate) (PtBA) or polystyrene (PS) side chains were synthesized using the sequential addition of macromonomers ring-opening metathesis polymerization (SAM-ROMP) grafting-through method. Small-angle neutron scattering (SANS) studies on dilute solutions of the two types of bottlebrush polymers provided noninvasive characterization of their structural dimensions and chain conformations. Simulated SANS traces, generated using coarse-grained molecular dynamics simulations, reproduced the distinctive features observed in the experimental SANS signals and provided necessary validation for data modeling. The combined analysis of experimental and simulated SANS signals yielded key structural and conformational parameters, including the bottlebrush radius, length, and Kuhn length as well as the excluded volume parameter and the correlation length of the polymer side chains. Importantly, the obtained structural parameters followed well-defined scaling laws as a function of the backbone and side chain degrees of polymerization, as predicted by mean field theories. In conclusion, these findings provide clear experimental and computational evidence of the interdependence of structural and conformational properties in an important class of polymer architectures.

36 MATERIALS SCIENCE↗

Enhanced shear stabilization of turbulence in NSTX

In studying a particular non-stationary NSTX L-mode plasma, we observed unexpectedly high levels of flux—first with quasilinear (TGLF) modeling and subsequently with nonlinear gyrokinetic simulations. Upon more detailed analysis, a novel confinement regime was discovered in which a modest increase in E x B shear (beyond baseline experimental estimates) rapidly reduced turbulent transport to levels consistent with power balance. This modest increase is plausible given the errors inherent to the estimation of shearing rates, and the added complexity of the non-stationary (time-dependent) power balance. Remarkably, an additional small increase in shear yields the familiar ion-neoclassical transport level with what appears to be the onset of high-k electron transport only. Although analyses using the TGLF-SAT2 model successfully capture numerous parametric dependencies of this plasma, TGLF does not reproduce the rapid E x B stabilization seen in CGYRO. We believe the results presented should help to better characterize the nonlinear physics of spherical tokamak confinement regimes, provide useful ST datasets for reduced model development, and motivate more accurate experimental diagnosis of E x B shearing rates.

Atomic and molecular collisions↗

The birth and evolution of solvated electrons in the water

The photo-induced radiolysis of water is an elementary reaction in biology and chemistry, forming solvated electrons, OH radicals, and hydronium cations on fast time scales. Here, we use an optical-pump terahertz-probe spectroscopy setup to trigger the photoionization of water molecules with optical laser pulses at ~400 nm and then time-resolve the transient solvent response with broadband terahertz (THz) fields with a ~90 fs time resolution. We observe three distinct spectral responses. The first is a positive broadband mode that can be attributed to an initial diffuse, delocalized electron with a radius of (22 ± 1) Å, which is short lived (<200 fs) because the absorption is blue-shifting outside of the THz range. The second emerging spectroscopic signature with a lifetime of about 150 ps is attributed to an intermolecular mode associated with a mass rearrangement of solvent molecules due to charge separation of radicals and hydronium cations. After 0.2 ps, we observe a long-lasting THz signature with depleted intensity at 110 cm -1 that is well reproduced by ab initio molecular dynamics. We interpret this negative band at 110 cm -1 as the solvent cage characterized by a weakening of the hydrogen bond network in the first and second hydration shells of the cavity occupied by the localized electron.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Computational Performance Bounds Prediction in Quantum Computing With Unstable Noise

Quantum computing has significantly advanced in recent years, boasting devices with hundreds of quantum bits (qubits), hinting at its potential quantum advantage over classical computing. Yet, noise in quantum devices poses significant barriers to realizing this supremacy. Understanding noise’s impact is crucial for reproducibility and application reuse; moreover, the next-generation quantum-centric supercomputing essentially requires efficient and accurate noise characterization to support system management (e.g., job scheduling), where ensuring correct functional performance (i.e., fidelity) of jobs on available quantum devices can even be higher-priority than traditional objectives. However, noise fluctuates over time, even on the same quantum device, which makes predicting the computational bounds for on-the-fly noise is vital. Noisy quantum simulation can offer insights but faces efficiency and scalability issues. Here, in this work, we propose a data-driven workflow, namely QuBound, to predict computational performance bounds. It decomposes historical performance traces to isolate noise sources and devises a novel encoder to embed circuit and noise information processed by a Long Short-Term Memory (LSTM) network. For evaluation, we compare QuBound with a state-of-the-art learning-based predictor, which only generates a single performance value instead of a bound. Experimental results show that the result of the existing approach falls outside of performance bounds, while all predictions from our QuBound with the assistance of performance decomposition better fit the bounds. Moreover, QuBound can efficiently produce practical bounds for various circuits with over 106 speedup over simulation; in addition, the range from QuBound is over 10× narrower than the state-of-the-art analytical approach.

Li, Jinyang [George Mason Univ., Fairfax, VA (Unit↗

Scintillating glass for precision calorimetry in nuclear physics

High-performance scintillator materials are needed for particle identification and measurements of energy and momentum of electromagnetic particles in modern nuclear physics experiments. As an example, the US Electron-Ion Collider, a unique collider with diverse physics topics, requires electromagnetic calorimetry enabling high-quality electron identification and detection in the momentum range of 0.3 to tens of GeV. The highest resolution in electromagnetic calorimeters can be provided by homogeneous materials, e.g., lead tungstate crystals. Inorganic glass scintillators have been investigated as an attractive and cost-effective alternative to crystals, that is also easier and faster to manufacture in mass production. In this paper, we discuss progress in the fabrication and characterization of recent scintillating glass samples on both test bench and beam tests. Further, the results are well-reproduced by simulation and are discussed in the context of the Electron-Ion Collider experimental requirements and bench-marked against lead tungstate crystals.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

Development of GaAs/Si and GaAs/Si monolithic structures for future space solar cells

The results of heteroepitaxial growth of GaAs and GaAlAs directly on Si are presented, and applications to new cell structures are suggested. The novel feature is the elimination of a Ge lattice transition region. This feature not only reduces the cost of substrate preparation, but also makes possible the fabrication of high efficiency monolithic cascade structures. All films to be discussed were grown by organometallic chemical vapor deposition at atmospheric pressure. This process yielded reproducible, large-area films of GaAs, grown directly on Si, that are tightly adherent and smooth, and are characterized by a defect density of 5 x 10(6) power/sq cm. Preliminary studies indicate that GaAlAs can also be grown in this way. A number of promising applications are suggested. Certainly these substrates are ideal for low-weight GaAs space solar ells. For very high efficiency, the absence of Ge makes the technology attractive for GaAlAs/Si monolithic cascades, in which the Si substrates would first be provided with a suitable p/n junction. An evaluation of a three bandgap cascade consisting of appropriately designed GaAlAs/GaAs/Si layers is also presented.

Spitzer, M. B.↗

A Compact, Solid-State UV (266 nm) Laser System Capable of Burst-Mode Operation for Laser Ablation Desorption Processing

Compared to wet chemistry and pyrolysis techniques, in situ laser-based methods of chemical analysis provide an ideal way to characterize precious planetary materials without requiring extensive sample processing. In particular, laser desorption and ablation techniques allow for rapid, reproducible and robust data acquisition over a wide mass range, plus: Quantitative, spatially-resolved measurements of elemental and molecular (organic and inorganic) abundances; Low analytical blanks and limits-of-detection ( ng g-1); and, the destruction of minimal quantities of sample ( g) compared to traditional solution and/or pyrolysis analyses (mg).

Laser↗

Integral Channel Nozzles and Heat Exchangers using Additive Manufacturing Directed Energy Deposition NASA HR-1 Alloy

Heat exchangers for use in propulsion applications are very critical components because they must be efficient, compact and light and often operate with working fluids at extreme temperatures or pressures or both. Various components and systems use heat exchangers such as combustion chambers of gas turbines and internal combustion engines, fuel cells (air supply and thermal management), electric batteries (thermal management), evaporators and recuperators of waste-heat-to-power systems, and rocket engines. Even if the results are more generally applicable, the heat exchangers applications to which this study is more closely related are regeneratively cooled rocket nozzles and chambers, and repressurization systems for the launch vehicles. These components are often thin-walled and contain pressurized fluids, like propellants at cryogenic or elevated temperatures. Given that the environments that these propulsion components must endure are challenging, the manufacturing to meet these specifications often require long lead times due to specialty processes and unique tooling associated with the combined thin-wall integral channel and large-scale structures. Additive manufacturing (AM) offers programmatic advantages for reduction in processing time and cost in addition to various technical advantages, including the possibility to achieve enhanced hardware complexity targeted to superior performance, part consolidation, and the capability of processing of novel alloys. While AM is already being utilized for heat exchanger components in propulsion applications, almost all these AM components are made by means of Laser Powder Bed Fusion (L-PBF). L-PBF allows for fine features but is rather limited with respect to the overall size of the components that can be manufactured. Recent developments are maturing the Laser Powder Directed Energy Deposition (LP-DED) process which may be used, for example, to make integral channel thin-wall regeneratively-cooled rocket nozzles with diameters greater than 1 m. This paper highlights some integral channel heat exchanger demonstrator hardware applications of LP-DED, as well as the characterization of this process in combination with the use of the NASA HR-1 alloy. To properly utilize LP-DED for heat exchanger manufacturing, various aspects are being characterized such as geometry limitations, measurement of surface texture and geometric angled surfaces, surface enhancements for internal channels, and material evaluation. NASA HR-1 (FeNi-Cr) is a high strength hydrogen resistant superalloy developed for use in aerospace applications, such as heat exchangers. Some aspects and considerations about the design of heat exchangers are summarized together with data relevant to LP-DED manufacturing in combination with the NASA HR-1 alloy. Microchannels were successful deposited down to 2.54 mm and 1 mm wall thickness, wall angles of 30°, both with high reproducibility. It was also found that the areal surface roughness is highly dependent on the size of the powder feedstock used for deposition. The characterization of these LP-DED features is critical for fluid flow and heat transfer predictions as it can be exploited to enhance heat transfer at the cost of increased pressure drop.

Additive Manufacturing↗

Integral Channel Nozzles and Heat Exchangers using Additive Manufacturing Directed Energy Deposition NASA HR-1 Alloy

Heat exchangers for use in propulsion applications are very critical components because they must be efficient, compact and light and often operate with working fluids at extreme temperatures or pressures or both. Various components and systems use heat exchangers such as combustion chambers of gas turbines and internal combustion engines, fuel cells (air supply and thermal management), electric batteries (thermal management), evaporators and recuperators of waste-heat-to-power systems, and rocket engines. Even if the results are more generally applicable, the heat exchangers applications to which this study is more closely related are regeneratively cooled rocket nozzles and chambers, and repressurization systems for the launch vehicles. These components are often thin-walled and contain pressurized fluids, like propellants at cryogenic or elevated temperatures. Given that the environments that these propulsion components must endure are challenging, the manufacturing to meet these specifications often require long lead times due to specialty processes and unique tooling associated with the combined thin-wall integral channel and large-scale structures. Additive manufacturing (AM) offers programmatic advantages for reduction in processing time and cost in addition to various technical advantages, including the possibility to achieve enhanced hardware complexity targeted to superior performance, part consolidation, and the capability of processing of novel alloys. While AM is already being utilized for heat exchanger components in propulsion applications, almost all these AM components are made by means of Laser Powder Bed Fusion (L-PBF). L-PBF allows for fine features but is rather limited with respect to the overall size of the components that can be manufactured. Recent developments are maturing the Laser Powder Directed Energy Deposition (LP-DED) process which may be used, for example, to make integral channel thin-wall regeneratively-cooled rocket nozzles with diameters greater than 1 m. This paper highlights some integral channel heat exchanger demonstrator hardware applications of LP-DED, as well as the characterization of this process in combination with the use of the NASA HR-1 alloy. To properly utilize LP-DED for heat exchanger manufacturing, various aspects are being characterized such as geometry limitations, measurement of surface texture and geometric angled surfaces, surface enhancements for internal channels, and material evaluation. NASA HR-1 (FeNi-Cr) is a high strength hydrogen resistant superalloy developed for use in aerospace applications, such as heat exchangers. Some aspects and considerations about the design of heat exchangers are summarized together with data relevant to LP-DED manufacturing in combination with the NASA HR-1 alloy. Microchannels were successful deposited down to 2.54 mm and 1 mm wall thickness, wall angles of 30°, both with high reproducibility. It was also found that the areal surface roughness is highly dependent on the size of the powder feedstock used for deposition. The characterization of these LP-DED features is critical for fluid flow and heat transfer predictions as it can be exploited to enhance heat transfer at the cost of increased pressure drop.

additive manufacturing↗

Innovative Method for Welding in Generation 3 CSP to Enable Reliable Manufacturing of Solar Receivers to withstand Daily Cycling at Temperatures Above 700°C (Final Technical Report)

Inconel® Alloy 740H® (alloy 740H) was the first age-hardenable nickel-based alloy approved by the ASME Boiler & Pressure Vessel Code for use in pressure-boundary applications. Over the past ~20 years the alloy has been optimized for weldability and high-temperature stability, approved for use in different applications. Development of a supply chain combined with the advantageous properties of the alloy (high-temperature creep strength, oxidation and corrosion resistance, etc.) have resulted in the alloy being applied to new high-temperature power cycle demonstration projects, and of particular interest are applications to concentrating solar power (CSP) to enable higher-efficiency Generation 3 CSP systems and the corresponding supercritical CO 2 (sCO 2 ) power cycle components (heat exchangers, piping, etc.). The high allowable stresses of alloy 740H also make it a desirable material for current Generation 2 CSP solar power receivers to improve cyclic capability and/or reduce receiver height. Recent experiences in demonstration projects utilizing alloy 740H identified cracking issues during welding and fabrication. In this project, a detailed study was done to confirm and clarify the Stress Relaxation Cracking (SRxC) mechanism, also known as stress relief cracking or strain-age cracking (SAC), during post-weld heat-treatment (PWHT). This involved detailed microscopy and advanced characterization to understand the root cause(s) of three failures obtained from industry. Based in-part on these findings, a targeted laboratory based SRxC test method was utilized to evaluate variables such as heat-to-heat variations, strain level, PWHT temperature, and starting material condition on three heats of alloy 740H. Industrial shop welding of cold-worked plates was also conducted. The research showed the following: SRxC was confirmed as the cracking mechanism for all field failures; Stress state (from residual stresses, constraint, deformation, and local stress concentrations) was playing a significant role in field failures and laboratory testing confirmed increasing susceptibility for all heats with increasing strain levels. High levels of microstructural strain were identified at crack initiation locations, in some cases leading to local recrystallization; Precipitate free zones (PFZs) at grain boundaries were found at relaxation cracks and crack initiation locations uniquely associated with SRxC in alloy 740H. Laboratory testing reproduced this microstructural feature which had only previously been reported in long-term creep testing of weldments. Advanced nano-scale characterization confirmed the presence of a moving boundary leading to coarsening of precipitates and PFZs where damage accumulated; The research suggested heat-to-heat variations due to local chemistry and processing may influence SRxC susceptibility, but more work is needed to fully clarify these effects. To disseminate the key learnings from this research to the scientific and engineering communities and alloy 740H end users, multiple technical publications and presentations were made, an industrial alloy 740H users meeting was held, and a new industry guideline specification document which can be directly implemented by end-users of alloy 740H was produced.

14 SOLAR ENERGY↗