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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Development of Refractory Alloys and Refractory Coatings for Advanced Nuclear Reactors

The next generation of nuclear reactors will benefit from materials that enable operation at higher temperatures (>500°C), higher irradiation doses (up to 200 displacements per atom (dpa)), and the use of more corrosive and reactive coolants. This work package represents the first experimental steps towards a longer-term effort to develop refractory materials for nuclear energy applications which will enable operation under these conditions. Specifically, this work package focuses on additive manufacturing of refractories as both a refractory liner coating deposited onto the interior surface of a metallic tubular backbone and as bulk refractory alloys. During fiscal year 23 (FY23), several refractory metal coating systems and bulk alloys were examined and selected using a decision criteria matrix. The refractory metal coating systems included molybdenum, tungsten, and zirconium as refractory coatings on backbones of either carbon-carbon (C/C) or silicon carbide-silicon carbide (SiC/SiC) ceramic matrix composites. The bulk refractory alloys included C-103, WTa, and WNiFe as bulk alloys. During FY24 additional bulk refractory alloys and metallic backbones were evaluated using the decision criteria matrix based on input from the AMMT leadership team. These included 316 SS and 316H SS for the metallic backbones and Mo-La, Ta, and Nb1Zr as bulk refractory alloys. The primary focus for the FY24 effort was placed on establishing the capabilities to deposit refractory coatings based on the results of the scoring in the decision criteria matrix and finalizing the additively manufactured TZM studies which were incorporated into the AMMT program from the microreactor program. Further efforts were dedicated to establishing the capabilities to additively manufacture down-selected bulk refractory alloys.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2015

High Chrome Refractory Characterization: Part I. Impact of Melt Reduction/Oxidation on the Corrosion Mechanism

High Cr 2 O 3 containing Monofrax ™ K‐3 is a robust refractory that is used in the fiberglass industry and used in radioactive waste glass melters worldwide. Monofrax ™ K‐3 is tolerant of transition metal oxides but contains highly reduced solid solutions of spinels, that is, (Mg,Fe 2+ )(Al,Cr) 2 O 3 . Conversely, many of the waste feeds being processed are highly oxidizing. The K‐3 refractory corrosion was tested in sealed crucibles starting with slurried melter feed instead of prereacted glass called for by ASTM C621. Testing the refractory coupon during the feed‐to‐glass conversion exposes the refractory to the oxidizing and reducing species being released during vitrification, for example, NO 3 − , NO 2 − , CO 2 , CO , O 2 . Corrosion rates measured in highly oxidizing (high nitrate) feeds were ~1.8–2.8 times higher than those determined using prereacted glass or reduced feeds. Confirmatory corrosion rates were measured on Monofrax ™ K‐3 coupons immersed in oxidizing feed in a 1/100th‐scale HLW pilot‐scale melter. Corrosion is heterogeneous or incongruent as Ni and Fe in the waste glass exchange with Mg and Al in the refractory. An insoluble NiFe 2 O 4 spinel corrosion product is formed that can build up a protective layer along the refractory walls or spall and settle to the melter floor depending on melt pool convection/agitation.

Jantzen, Carol M.↗
DOE OSTI2025

The Path towards Plasma Facing Components: A Review of State-of-the-art in W-Based Refractory High-Entropy Alloys

Developing advanced materials for plasma-facing components (PFCs) in fusion reactors is a crucial aspect for achieving sustained energy production. Tungsten (W) - based refractory high-entropy alloys (RHEAs) have emerged as promising candidates due to their superior radiation tolerance and high-temperature strength. This review paper will focus on recent advancements in W-based RHEA research, particularly emphasizing the key role of modelling using machine learning (ML) in the stage of discovery by predicting properties for each composition and expediting the identification of optimal RHEA compositions with desired properties. Additionally, the application of additive manufacturing (AM) techniques for fabricating W-based RHEAs is explored, highlighting their advantages for rapid prototyping and multi-compositional sample production in a high throughput manner. The review critically evaluates the current understanding of mechanical properties relevant to PFC applications, including high-temperature strength and ductility. Furthermore, the radiation tolerance of W-based RHEAs under irradiated conditions is discussed. Finally, the validity of current AM-manufactured W-based RHEAs as PFC materials is assessed, and key challenges and opportunities for future research are identified. This review aims to provide a comprehensive overview of W-based RHEAs for fusion applications and their potential to guide the development and validation of advanced refractory high entropy alloys.

Hatler, Caleb [University of Wisconsin-Madison]↗
DOE OSTI2015

High Chrome Refractory Characterization: Part II . Accumulation of Spinel Corrosion Deposits in Radioactive Waste Glass Melters

High Cr 2 O 3 containing Monofrax ™ K‐3 is a robust refractory that is used in radioactive waste glass melters worldwide. Monofrax ™ K‐3 contains highly reduced phases. Conversely, many of the radioactive feeds being processed are highly oxidizing. The K‐3 refractory corrosion rates in oxidizing (high nitrate) feeds were ~1.8–2.8 times higher than the rates determined using reducing feeds. The corrosion product formed is a mixture of spinel and glass (slag) that can accumulate on the melter floor. A methodology to calculate the depth of slag deposits from refractory corrosion is presented and verified with slag measurements from the Defense Waste Processing Facility ( DWPF ) melter after it had processed oxidized feeds for 1.75 years. The calculations show that had the facility continued to process oxidized feeds the melter lifetime (based on when the deposits could have reached and blocked the pour spout riser) would have been ~4.5 years. The DWPF changed to a reducing flow sheet after ~3 years of operation. The lifetimes of Melter #1 and Melter #2, assuming a failure due to pour spout blockage, are calculated as 7.7–12 years based on corrosion rates measured with reducing feeds. Lifetimes of 9 and >11 years have actually been achieved.

Jantzen, Carol M.↗
DOE OSTI2019

Interaction of Iron with Alumina Refractory Under Flash Ironmaking Conditions

A novel flash ironmaking technology (FIT) based on the direct reduction of iron ore concentrate by a reducing gas such as hydrogen, natural gas, or coal gas has been developed at the University of Utah. A proper choice of refractories is expected to play an important role in the development of FIT and its scale-up. In this work, the interaction of iron with alumina refractory under flash ironmaking conditions has been investigated. A thermodynamic basis for the interaction phenomena has been developed by considering the Fe-Al-O system, and a kinetic model based on solid-state diffusion is proposed to describe the growth of the hercynite (FeAl{sub 2}O{sub 4}) spinel formed as a result of the interaction between Fe, O (from H{sub 2}O and CO{sub 2}), and Al{sub 2}O{sub 3}. Experiments were conducted with Fe powders and pure Al{sub 2}O{sub 3} in the temperature range 1200 to 1500 °C under gas atmospheres relevant to flash ironmaking, and the reacted samples were analyzed using XRD, SEM-EDX, and EPMA techniques. The analyses of reacted samples confirmed the formation of the hercynite (FeAl{sub 2}O{sub 4}) spinel phase and the thickness of the FeAl{sub 2}O{sub 4} spinel as measured using elemental line scans in SEM-EDX and EPMA varied in the range of 0.5 to 1.3 mm. Results showed that the proposed model suitably describes the growth of the hercynite spinel layer, which obeyed the parabolic rate law at all temperatures. The parabolic rate constants were obtained and the diffusion-controlled growth of the FeAl{sub 2}O{sub 4} layer strongly depended on temperature. Furthermore, using the kinetic model, an expression for the effective diffusivity ( (D{sub eff})-bar ) was obtained and its values at the experimental temperatures were determined. The solid-state diffusion was an activated process, as expected, with an activation energy value of 231 kJ/mol.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Computational exploration of biomedical HfNbTaTiZr and Hf 0.5 Nb 0.5 Ta 0.5 Ti 1.5 Zr refractory high-entropy alloys

Refractory high entropy alloys (RHEAs) have been proven to be a potential candidate in the biomedical field due to their balanced mechanical properties and biocompatible composition. Recent experimental findings show that RHEAs like HfNbTaTiZr and Hf 0.5 Nb 0.5 Ta 0.5 Ti 1.5 Zr have good mechanical properties such as high polarization and wear resistance than others which establish them as potential materials for biomedical application. In this work, we performed first-principles density functional theory calculations on the mechanical and thermal properties of HfNbTaTiZr and Hf 0.5 Nb 0.5 Ta 0.5 Ti 1.5 Zr. The predicted lattice constant, density, Young's modulus, and Vickers hardness are consistent with the available experimental report, which verifies the accuracy of the applied model. The thermal coefficient of linear expansion of both RHEAs has been investigated by utilizing the Debye theory. The present methods could be applied to study other future RHEAs on exploration of their physical properties.

36 MATERIALS SCIENCE↗