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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Reconstitution of Sandia's Melt Laboratory: A Strategic Approach to Address Alloy Procurement and Quality Challenges - Part 1

In recent years, the procurement of essential materials such as Stainless Steels, Ni-Alloys, and Kovar has become increasingly challenging. Lead times for these materials have extended to over 24 months, placing significant stress on the reliability of attaining these alloys. This situation is exacerbated by the supplier’s minimum purchase requirement of excessively large quantities to meet unique purchase order (PO) requirements which is usually above the maximum requirements of Sandia National Laboratories (SNL). Additionally, the reluctance of foundries to engage in small lot development for SNL specific needs further complicates the procurement process. This white paper explores the reconstitution of SNL’ Melt Laboratory as a strategic solution to mitigate these challenges.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Computational Design of Interlayers for Thermally Stable Compositionally Graded Coatings on Nickel Alloys

To extend the service life of Ni-based superalloys, refractory metal coatings are often used. However, direct bonding between metals with dissimilar crystal structure promotes brittle intermetallic phase formation. This work presents a computational thermodynamic framework for high throughput design of functionally graded interlayers to suppress deleterious phases that may form at the interlayer. The Thermo-Calc software package was used to screen candidate metallic interlayer elements based on stability of solid-solution phases. Vanadium was identified as a promising interlayer due to its consistent suppression of intermetallic phases. Temperature-dependent phase diagram mapping between 600 and 1000 °C guided selection of a compositional pathway that significantly reduced intermetallic formation compared to directly joining the Ni-based and Nb refractory alloys. Time–temperature–transformation analysis was performed to assess whether equilibrium-predicted phases are kinetically accessible along regions of the graded path where non-solid-solution phases are not fully suppressed. The methodology was further applied to additional Ni-based alloy and coating systems, illustrating its transferability as an approach for rapid computational design of graded interlayers in dissimilar high-temperature materials.

36 MATERIALS SCIENCE↗