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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 235 records · Page 13

Elucidating the Initial Steps in α-Uranium Hydriding Using First-Principles Calculations

Hydrogen embrittlement of uranium, which arises due to the formation of a structurally weak pyrophoric hydride, poses a major safety risk in material applications. Previous experiments have shown that hydriding begins on the top or near the surface (i.e., subsurface) of α-uranium. However, the fundamental molecular-level mechanism of this process remains unknown. Here, in this work, starting from pristine α-U bulk and surfaces, we present a systematic investigation of possible mechanisms for the formation of metal hydride. Specifically, we address this problem by examining the individual steps of hydrogen embrittlement, including surface adsorption, subsurface absorption, and the interlayer diffusion of atomic hydrogen. Furthermore, by examining these processes across different facets, we highlight the importance of both (1) hydrogen monolayer coverage and (2) applied tensile strain on hydriding kinetics. Taken together, by studying previously overlooked phenomena, this study provides foundational insights into the initial steps of this overall complex process. We anticipate that this work will guide near-term future development of multiscale kinetic models for uranium hydriding and subsequently identify potential strategies to mitigate this undesired process.

36 MATERIALS SCIENCE↗

Multilayer Architecture Barriers for High Temperature Nuclear Applications

Innovative thin film multilayer metal/ceramic barrier coatings have been developed by Argonne National Laboratory to protect fuel cladding against different phenomena that can be encountered under the harsh operating conditions of advanced nuclear reactors. One phenomenon is Fuel-Cladding Chemical Interaction (FCCI), which can represent a challenge to the performance of steel-clad metallic fuels in sodium-cooled fast reactors (SFRs), especially when operating to high burnups at elevated cladding temperatures, and long fuel residence time. Another phenomenon is the corrosion of zirconium-based cladding under prototypic boiling water reactor (BWR) conditions and associated cladding during off normal conditions, including loss of coolant accidents (LOCA). This work provides details of the development and testing of a thin film (few microns) multilayer metal/ceramic (CrY/Y 2 O 3 ) coatings on steel cladding and its performance against FCCI. The coating architecture evolved through systematic mechanical testing, radiation tolerance assessments, and high-temperature diffusion studies from a preliminary multilayer concept to an optimized high-performance design. The optimized structure leverages stoichiometric Y 2 O 3 for its exceptional radiation stability, chemical inertness, and ultra-low fission product diffusivity (e.g., Ce diffusivity ~10 -20 m 2 /s in irradiated Y 2 O 3 at 650 °C). This is paired with ductile chromium-rich interlayers (Cr 95 Y 5 ), which significantly enhance fracture toughness and mechanical resilience. Design refinements, including increased ceramic layer thickness and optimized Cr–Y interlayer composition, eliminated fracture propagation and preserved coating integrity under extreme mechanical stress (>10× typical reactor conditions) and prolonged radiation exposure (~300 dpa). Those conditions are well beyond expected conditions during normal operations in SFR, and cover some of the transient conditions as well. In addition, the coating deposition was demonstrated to be applied uniformly to the inner surface of steel tubes representing prototypic SFR cladding. Another phenomenon under consideration in this work is the corrosion of zirconium-based cladding under prototypic boiling water reactor (BWR) conditions and associated off normal conditions including loss of coolant accident (LOCA). Another multilayer thin film coating is considered for mitigation of this phenomenon, where a coating of yttrium aluminum and yttrium aluminum ceramic/metal thin film coating. Preliminary results on the coating performance during high temperature thermal cycling (up to 1000 C) have shown promising performance of the coating. On-going optimization of the coating will continue in FY26.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

The TRANSCEND Consortium - In-situ Identification of Surface Corrosion Products on Spent Nuclear Fuels - 20276

The management of spent nuclear fuel is a major ongoing concern for the UK owing to the cessation of reprocessing operations at Sellafield and the large, complex inventory arising from Magnox, AGR, PWR and prototype reactors. Retrieval and relocation operations for legacy fuels are imminent and therefore, any models that enhance our understanding of fuel evolution will help mitigate the risks associated with fuel storage and disposal. The TRANSCEND Consortium on nuclear waste management comprises four work packages, within this current paper we provide a summary overview of progress to date and illustrative results from Theme 3: Spent Nuclear Fuels. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Hydrogen production with seawater-resilient bipolar membrane electrolyzers

Generation of H 2 and O 2 from untreated water sources represents a promising alternative to ultrapure water required in contemporary proton exchange membrane-based electrolysis. Bipolar membrane-based devices, often used in electrodialysis and CO 2 electrolysis, facilitate impure water electrolysis via the simultaneous mediation of ion transport and enforcement of advantageous microenvironments. Herein, we report their application in direct seawater electrolysis; we show that upon introduction of ionic species such as Na + and Cl - from seawater, bipolar membrane electrolyzers limit the oxidation of Cl - to corrosive OCl - at the anode to a Faradaic efficiency (FE) of 0.005%, while proton exchange membrane electrolyzers under comparable operating conditions exhibit up to 10% FE to Cl oxidation. In conclusion, the effective mitigation of Cl - oxidation by bipolar membrane electrolyzers underpins their ability to enable longer-term seawater electrolysis than proton exchange membrane assemblies by a factor of 140, suggesting a path to durable seawater electrolysis.

08 HYDROGEN↗

Safety Benefits Assessment for Accident Tolerant Fuels in Consideration of Steam Generator Tube Degradation Using Dynamic Event Tree Analysis

Accident tolerant fuel (ATF) is expected to delay or prevent core damage by providing additional coping time under accidents involving loss of core cooling. The effect of extended coping time may vary depending on the plant response to accidents. Age-related component degradation that deteriorates plant performance over time could have an impact on the actual advantages of ATF. The potential safety benefits of two near-term ATF candidates, including Cr-coated Zr cladding and FeCrAl cladding, are assessed for a 2-in. loss-of-coolant accident with failed high-pressure safety injection using the dynamic event tree (DET) approach considering possible stress corrosion cracking of steam generator (SG) tubing under aging. The DET approach allows likelihood quantification of accident sequences leading to core damage, including stochastic variation of system response and human actions during accident mitigation. The safety benefits of the selected ATF claddings in terms of additional coping time and the core damage frequency reduction rate under specified accident situations were quantitatively estimated. The results show that the deployment of the two selected ATF claddings is expected to lead to longer coping times and lower core damage frequency due to the wider safety margin to peak cladding temperature they provide. The safety advantages would be greater as SG tube degradation proceeds. Thus, the two ATF candidates would lead to less severe consequences in terms of likelihood of core damage and susceptibility to the SG tube degradation than UO 2 -Zr fuel.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Review and Summary of Oxide Thickness Data for Aluminum-Clad Spent Nuclear Fuel

The U.S. Department of Energy (DOE) owns a large inventory of aluminum-clad spent nuclear fuel (ASNF) in interim storage pending ultimate disposition, with more being generated by currently operating research reactors. Dry storage in sealed DOE Standard Canisters is being investigated as an approach for long-term interim storage and/or disposition in a repository for ASNF. A primary challenge for ASNF storage is the presence of aluminum (oxy)hydroxide layers formed on the cladding surfaces during water exposure in the reactor and in wet storage, which forms a reservoir of chemisorbed water not readily removed at low (<100°C) drying temperatures. Free, physisorbed, and chemisorbed water are all susceptible to radiolytic breakdown under irradiation and can release hydrogen gas. Identifying the likely range of (oxy)hydroxide loadings on ASNF that may be placed in dry storage will help to ensure that the impact of the (oxy)hydroxide is adequately accounted for while avoiding over conservatism and enable mitigation strategies to be implemented where needed. The current report summarizes information on (oxy)hydroxide thicknesses and characteristics from the literature and from recent measurements taken in the present research campaign. In general, corrosion studies have indicated that the corrosion and oxide buildup on aluminum are affected by numerous conditions, including pH, temperature and heat flux, coolant flowrates, irradiation (in-reactor vs. unirradiated tests), duration of water exposure, and the amount of oxide already on the surface. Some of these factors are interrelated (e.g., the local temperature, heat flux, and coolant flowrate). Observations of the impact of irradiation (in-reactor versus ex-reactor measurements) on corrosion and oxide thickness are mixed, but multiple studies indicate that there is a significant difference between in-reactor and ex-reactor corrosion kinetics, even when other operating conditions such as pH, flowrate, heat flux, etc., simulate those in a reactor.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

QuEST: Qualifying Environmentally Sustainable Technologies, Volume 5

This edition of the QuEST newsletter contains brief articles that discuss the NASA Technology Evaluation for Environmental Risk Mitigation (TEERM) program, and the importance of collaboration, efforts in materials management and substitution for coatings for launch structures, Low volatile organic compound (VOC) Coatings Field Testing, Non-Chrome Coating Systems, Life Cycle Corrosion Testing, Lead-Free Electronics Testing and Corn Based Depainting and efforts in Pollution Control in the area of Hypergolic Propellant Destruction Evaluation, efforts in development of alternative energy in particular Hydrogen Sensors, Energy and Water Management, and efforts in remediation in the removal of Polychlorinated Biphenyl (PCB) contamination

Lewis, Pattie↗

HPC for the EEC: Industrial Trade Tools for the Aging Energy Infrastructure

The petrochemical and refining sectors are challenged with reliably delivering safer and cleaner energy to US consumers, while meeting an ever-growing global demand. The petrochemical and refining infrastructure in the USA is aging, and corrosion and damage mechanisms are constant threats to mechanical integrity, safety, and profitability. However, governments and industry stakeholders are reluctant to replace or upgrade the existing infrastructure due to the immense cost. To better understand and mitigate the risks of aging energy infrastructure, strong technical analysis capabilities, combined with optimized monitoring and decision making, is critical. Today, this is accomplished via complex simulations and data analysis. To this end, advanced High-Performance-Computing (HPC) software will be leveraged and integrated in easy-to-use industrial trade tools, to lower the barrier for new users, increase the ease of access for experienced users, and allow for smarter decisions to be made in the midstream and downstream energy sectors.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Interfacial pressure improves calendar aging of lithium metal anodes

Lithium (Li) metal is a promising anode because its theoretical specific capacity is approximately ten times larger than graphite. However, Li anodes suffer from long-term capacity fade due to Li stranding (becoming electronically disconnected) and electrolyte decomposition. Applied interfacial pressure has been shown to improve Li anode cycling, likely due to reincorporating stranded or “dead” Li into the anode. Calendar aging can also lead to Li capacity loss due to electrolyte decomposition/Li corrosion and the formation of stranded Li. Some research suggests that calendar aging during cycling results in reversible capacity losses due to Li stranding and reconnection. We here investigate the effect of applied interfacial pressure on Li anode calendar aging during cycling with incorporated rest steps in a localized high-concentration electrolyte (LHCE) to understand if pressure can mitigate stranded Li formation during rest by manipulating the Li morphology. Pouch cells exhibit more stable cycling and denser Li deposits between 10 kPa and 1,000 kPa of applied pressure compared to no applied pressure. Despite drops in CE during periodic rest cycles, the average cumulative lost capacity and average coulombic efficiency (CE) of cells over 50 cycles show that cells aged with incorporated rest steps perform similarly to cells cycled without added rests. This similar average CE suggests that dead Li is largely responsible for drops in CE during rest rather than irreversible Li corrosion and that the dead Li can be reconnected in subsequent cycling. The addition of a lithiophilic ZnO coating to the Cu working electrode increases the adhesion and coverage of Li deposits at low pressures and improves CE during the first cycle.

25 ENERGY STORAGE↗

Quarterly Research Performance Progress Report

The goal of this project is to develop a high temperature, high-pressure well integrity evaluation device that can operate in enhanced geothermal system (EGS) boreholes without active cooling or substantial mitigation of borehole conditions. The product must provide consistent high resolution data regarding the efficacy of wellbore casing and cement for long-term operation. This project aims to deliver a ruggedized tool that can withstand a corrosive geothermal environment with pressure ranges up to 15,000 psi and temperatures up to 250°C for a 24-hour operating period.

15 GEOTHERMAL ENERGY↗

Mitigating Iodine Diffusion by a MoO 3 –Organic Composite Hole Transport Layer for Stable Perovskite Solar Cells

Halide perovskite solar cells (PSCs) exhibit commercialization potential, but long-term stability still must be addressed. Among various products of perovskite decomposition, iodine species are of considerable concern due to their high vapor pressure and corrosive nature. To address this, a small-molecule hole transport layer (HTL), 4,4',4"-tris[(3-methylphenyl)phenylamino]triphenylamine (m-MTDATA), is used; mixing it with molybdenum trioxide (MoO3) p-dopes the layer and slows iodine permeation. Furthermore, we demonstrate that m-MTDATA:MoO3 HTLs employed in PSCs improve stability under both thermal and voltage bias stress compared to devices with a conventional doped 2,2',7,7'-tetrakis[N,N-di(4-methoxyphenyl)amino]-9,9'-spirobifluorene (spiro-OMeTAD) HTL.

14 SOLAR ENERGY↗

Corrosion of a-Si cells and modules

The authors report on corrosion/erosion phonemena observed in exposing a-Si cells, modules, and specially designed test structures to natural and accelerated test environments. Relevant cell and module I-V curve data used for monitoring degradation are presented. The causes of the observed degradation, methods of mitigation, and consequences for fielded modules are discussed.

Mon, G. R.↗

Effect of moisture ingression on material performance and particle generation in molten salts

This report summarizes activities conducted to understand and mitigate the negative consequences that moisture ingressions have upon the operations of pyroprocessing equipment. The objectives of the work conducted in FY25 were to characterize (1) the physicochemical properties of particles generated as a result of moisture ingressions, and (2) the corrosion of relevant structural materials with the introduction of moisture. Compositional and morphological analyses of the generated particles were conducted through a suite of characterization technologies, including X-ray diffraction, microscopy, and particle size analysis. The results gathered this year were compared to those obtained in FY24 when studies with oxygen ingressions were conducted on CeCl 3 -LiCl-KCl and UCl 3 -LiCl-KCl systems. Investigations involving performance evaluations of industrially relevant structural alloys were also conducted under moisture ingress conditions. In-line electrochemical monitoring of the bulk salt was augmented with microscopy of alloy samples to quantify the concentration and accumulation of corrosion products in the bulk salt. The results reported in this work provide a more holistic understanding of the effects of atmospheric ingressions on molten chloride salt chemistry such that effective redox control strategies may be implemented.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Inaugural Molten Salt Technologies Workshop Powering the Future

The inaugural “Molten Salt Technologies – Powering the Future” Workshop marked a significant convergence of minds from diverse industries, each harnessing molten-salt technologies in innovative ways. Participants from sectors such as solar, geothermal, and advanced nuclear energy, as well as those involved in cutting-edge applications like thermal transport and rare-earth metals extraction, gathered to discuss their shared technical challenges and opportunities. Industry leaders in metal extraction and recycling, alongside experts in high-temperature sensor technology and advanced material manufacturing, also brought their unique perspectives to the table. This workshop served as a crucial platform for these varied industries to delve into the engineering intricacies that molten salt technologies entail. Common challenges such as understanding the thermophysical properties of salts, tackling corrosion mechanisms in harsh environments, and enhancing material resilience under extreme conditions were at the forefront of discussions. These technical sessions highlighted the critical need for cross-industry collaboration to address issues like salt life-cycle process engineering, impurity mitigation, and the development of durable, high-performance materials. By bringing together academia, industry, and representatives from national laboratories and the U.S. Department of Energy (DOE), the workshop facilitated a rich exchange of knowledge and experiences. This interaction not only fostered new partnerships but also strengthened the network among existing collaborators, setting the stage for joint solutions to the complex problems faced by all sectors using molten salt technologies. The event underscored the importance of collaborative efforts in overcoming common engineering challenges and advancing the application of molten-salt technologies across various industries. The workshop not only provided an essential forum for networking and idea exchange but also highlighted the collective drive towards innovative solutions that could benefit multiple fields.

Department of Energy↗

Inaugural Molten Salt Technologies Workshop Powering the Future

The inaugural “Molten Salt Technologies – Powering the Future” Workshop marked a significant convergence of minds from diverse industries, each harnessing molten-salt technologies in innovative ways. Participants from sectors such as solar, geothermal, and advanced nuclear energy, as well as those involved in cutting-edge applications like thermal transport and rare-earth metals extraction, gathered to discuss their shared technical challenges and opportunities. Industry leaders in metal extraction and recycling, alongside experts in high-temperature sensor technology and advanced material manufacturing, also brought their unique perspectives to the table. This workshop served as a crucial platform for these varied industries to delve into the engineering intricacies that molten salt technologies entail. Common challenges such as understanding the thermophysical properties of salts, tackling corrosion mechanisms in harsh environments, and enhancing material resilience under extreme conditions were at the forefront of discussions. These technical sessions highlighted the critical need for cross-industry collaboration to address issues like salt life-cycle process engineering, impurity mitigation, and the development of durable, high-performance materials. By bringing together academia, industry, and representatives from national laboratories and the U.S. Department of Energy (DOE), the workshop facilitated a rich exchange of knowledge and experiences. This interaction not only fostered new partnerships but also strengthened the network among existing collaborators, setting the stage for joint solutions to the complex problems faced by all sectors using molten salt technologies. The event underscored the importance of collaborative efforts in overcoming common engineering challenges and advancing the application of molten-salt technologies across various industries. The workshop not only provided an essential forum for networking and idea exchange but also highlighted the collective drive towards innovative solutions that could benefit multiple fields.

Department of Energy↗

Long-term thermal aging of parylene conformal coating under high humidity and its effects on tin whisker mitigation

Usage of pure tin (Sn) or Sn-rich alloy in electronics industry is growing, which makes them more susceptible to the spontaneous growth of tin whiskers. The risk of having these whiskers can be dramatically mitigated by applying a conformal coating provided that it not only possesses excellent mechanical and adhesion properties but also maintains these properties throughout their service. Parylene C is commonly used as a conformal coating because of its favorable mechanical and physical properties, as well as superior conformal coverage. The purpose of this paper is to investigate the degradation of parylene C coating during the thermal aging in high humidity environment (85°C/85% relative humidity for up to 5000hrs) and its effect on the tin whisker mitigation capacity. It was observed that during aging at high temperature and high humidity (HTHH) environment, the oxidation occurs at early times, followed by bond scission, resulting in the loss of strength of the coating. Thinner parylene coating (12.5-μm-thick) had better coating adhesion on the silane-treated tin surface, so provided the better protection for tin whisker penetration than the thicker counterpart (25-μm-thick). After 2500hrs of aging, due to the degradation of the silane agent at the tin/parylene interface, the adhesion of the parylene coating was significantly weakened on the tin surface, which resulted in extensive corrosion of the tin solderpads. The loss of adhesion of the coating, along with the corrosion of the tin surface facilitated the tin whisker nucleation at the interface while the loss of mechanical strength and the brittleness made the coating easily penetrated by the growing whiskers. Tin whiskers with a smaller diameter were buckled and grew along the delaminated region while those with a larger diameter penetrated and continued to grow through the coating. Hence, the effectiveness of the parylene coatings on tin whisker mitigation is significantly reduced under long exposure to such high temperature and high humidity.

36 MATERIALS SCIENCE↗

The Role of Water on the Interfacial Adhesion in Si Solar Modules

Delamination of solar module interfaces often occurs in field-tested solar modules after decades of service due to environmental stressors such as humidity. As water diffuses into the module, failure mechanisms like corrosion and delamination are significantly affected. In the presence of water, the interfaces between EVA and the cell, glass, and backsheet all experience losses of adhesion exposing the module to accelerated degradation. Understanding the relation between interfacial adhesion and water content inside PV modules can help mitigate detrimental power losses. Water content measurements via short wave infrared reflectometry combined with 180 degrees peel tests were used to study and quantify the effect of water ingress and egress on adhesion. Changes in adhesion strength for different module interfaces are quantified, correlating spatial distribution of water content to adhesion for damp heat and dry heat exposed samples. After 1000 hours of damp heat exposure, decreases in adhesion strength of approximately 1 N/mm were noted for all interfaces.

adhesion↗

Current EBC Development and Testing at NASA

SiC SiC Ceramic Matrix Composites (CMCs) are a game changer for advanced power generation equipment because of their high temperature capability, oxidation resistance, and light weight that translate to significant reduction in fuel consumption and emission. Limitations of SiC SiC CMCs include surface recession and component cracking and associated chemical and physical degradation in the CMC. The solution pursued to mitigate surface recession of SiC SiC CMCs is the incorporation of coating systems that provide surface protection, which has become known as an Environmental Barrier Coating (EBC). The development of EBCs for the protection of SiC SiC CMCs was a continuation of coating development work for corrosion protection of silicon-based monolithics. The first and second generation EBCs developed in mid 1990s-early 2000s laid the foundation for current EBCs. Environmental degradation that limits EBC life includes surface recession by steam, oxidation in steam environments, and CMAS-EBC reactions. Many engine tests have been conducted since late 1990s and a first CMC component entered into service in 2016 in a commercial engine. The introduction of CMCs represents significant challenges as failure of the EBC means rapid reduction in component life. A reliable lifing method and engine-relevant testing methods to validate life need to be developed. This paper will current activities on EBC development and testing at NASA.

CMC↗