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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
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Potentiodynamic Polarization of Pure Metals and Alloys in Molten LiF-NaF-KF (FLiNaK) Using the K/K + Dynamic Reference Electrode

The potentiodynamic polarization method using the K/K + dynamic reference electrode was used to understand the corrosion behavior of Ni, Fe, Cr, the Ni-20Cr binary alloy, and 316L stainless steel in molten 46.5LiF-11.5NaF-42KF (FLiNaK, composition in mol %) salt at 700 °C. Exposure of the materials without an applied potential revealed that Ni and Fe were stable in FLiNaK, but Cr was dissolved rapidly. The apparent redox potentials of each material with respect to the K/K + redox couple are compared to gain insight into how the applied potential relates to the dominant corrosion mechanism for each alloy. Furthermore, the polarized pure metals experienced uniform surface recession while corrosion in the alloys resulted in preferential elemental dissolution depending on the applied potential with respect to the K/K + reference reaction.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Significant slowdown of plasma-optimized surface energy deactivation by vacuum sealing for efficient adhesive bonding

This work proposes an approach to minimize surface energy deactivation of plasma-treated metal and carbon fiber-reinforced polymer (CFRP) surfaces by vacuum sealing. Plasma treatments enhance adhesive wettability on post-treated surfaces for adhesive joints, but the treated surfaces deactivate quickly in air. The surface energy of aluminum alloy AA6061 and carbon fiber-reinforced polymer-polyamide (CFRP-PA66) optimally treated by a blown air plasma instrument returns to the original surface energy within one hour. Vacuum sealing of AA6061 and CFRP-PA66 reduced the surface energy deactivation over 7 days by at least 230 times and 970 times compared to in air. Double Cantilever Beam (DCB) tests performed on adhesively-bonded AA6061/CFRP-PA66 joints showed that the total energy release and energy dissipation before failure of plasma-treated and vacuum-sealed materials was up to 60% more than plasma-treated materials without vacuum sealing and up to 125% more than non-plasma-treated materials.

42 ENGINEERING↗
DOE OSTI2024

Formation of (Rh–Fe)–FeO x Complex Sites Enables Methanol Synthesis from CO 2

Here, we addressed the challenges of designing catalysts for selective CO 2 hydrogenation by incorporating oxide Fe species onto Rh nanoparticles. Nanoscopic FeO x domains created a “reverse catalyst” structure (i.e., a metal oxide supported on a metal) that increased the density of interfacial sites compared to traditional supported catalysts. The contact between the metal nanoparticle and the oxide overlayer induced the formation of a surface Rh-Fe alloy that stabilize methoxy groups while suppressing hydrogenolysis to methane. Sites at FeO x -metal interfaces interact with CO 2 sevenfold stronger than sites on metal surfaces, show larger energy barriers to cleave the C-O bonds, and offer a barrierless pathway for hydrogenation of methoxy species to methanol. Consequently, the multifunctional sites over FeO x /Rh-Fe catalysts highlight and meet the requirements of a selective methanol catalyst: strong interaction with CO 2 to ensure high density of transition states; metal sites to activate and make hydrogen available to surface intermediates; and high energy barriers for C-O bond cleavage to form carbides. These synthesis and catalytic chemistries, demonstrated for Rh-Fe-FeO x interfaces, enable us to overcome the limitations to the design of methanol production catalysts.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Controlling Hydrocarbon (De)Hydrogenation Pathways with Bifunctional PtCu Single-Atom Alloys

The conversions of surface-bound alkyl groups to alkanes and alkenes are important steps in many heterogeneously catalyzed reactions. On the one hand, while Pt is ubiquitous in industry because of its high activity toward C–H activation, many Pt-based catalysts tend to overbind reactive intermediates, which leads to deactivation by carbon deposition and coke formation. On the other hand, Cu binds intermediates more weakly than Pt, but activation barriers tend to be higher on Cu. We examine the reactivity of ethyl, the simplest alkyl group that can undergo hydrogenation and dehydrogenation via β-elimination, and show that isolated Pt atoms in Cu enable low-temperature hydrogenation of ethyl, unseen on Cu, while avoiding the decomposition pathways on pure Pt that lead to coking. Lastly, we confirm the predictions of our theoretical model and experimentally demonstrate that the selectivity of ethyl (de)hydrogenation can be controlled by changing the surface coverage of hydrogen.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Surface oxygenation of multicomponent nanoparticles toward active and stable oxidation catalysts

Abstract The need for active and stable oxidation catalysts is driven by the demands in production of valuable chemicals, remediation of hydrocarbon pollutants and energy sustainability. Traditional approaches focus on oxygen-activating oxides as support which provides the oxygen activation at the catalyst-support peripheral interface. Here we report a new approach to oxidation catalysts for total oxidation of hydrocarbons (e.g., propane) by surface oxygenation of platinum (Pt)-alloyed multicomponent nanoparticles (e.g., platinum-nickel cobalt (Pt–NiCo)). The in-situ/operando time-resolved studies, including high-energy synchrotron X-ray diffraction and diffuse reflectance infrared Fourier transform spectroscopy, demonstrate the formation of oxygenated Pt–NiOCoO surface layer and disordered ternary alloy core. The results reveal largely-irregular oscillatory kinetics associated with the dynamic lattice expansion/shrinking, ordering/disordering, and formation of surface-oxygenated sites and intermediates. The catalytic synergy is responsible for reduction of the oxidation temperature by ~100 °C and the high stability under 800 °C hydrothermal aging in comparison with Pt, and may represent a paradigm shift in the design of self-supported catalysts.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

CO and H 2 adsorption on Au-Ni bimetallic surfaces: a combined experimental and DFT theoretical study

Au-Ni bimetallic thin films were grown on refractory metal substrates. CO and H 2 adsorption on Au-Ni bimetallic surfaces have been studied by a combination of in situ polarization modulation infrared reflection absorption spectroscopy (PM-IRRAS), temperature-programmed desorption (TPD), and density functional theory (DFT) calculations. It is found CO desorption peak shifts from 413 K on pure Ni surfaces to 293 K on the isolated Ni atoms formed by alloying with Au atoms. The sharp decrease of CO desorption temperature on Au-Ni surfaces with increasing Au coverage is caused by the change of the favored CO adsorption sites from bridge/hollow sites on pure Ni surfaces to Ni top sites on Au-Ni bimetallic surfaces. In situ PM-IRRAS shows two CO adsorption bands on Au sites at 2119 cm −1 and 2103 cm −1 on Au-Ni surfaces at 80 K, which are due to CO bound on under-coordinated Au atoms and electron negatively charged Au sites modified with nearby Ni atoms, respectively. Even with the Au-Ni surface temperature at as low as 100 K, CO adsorption induced Ni surface segregation has been observed by in situ PM-IRRAS. Furthermore, DFT calculation results discover the adsorption energy of CO on Ni top sites continues to decrease with increasing Au coverage due to the geometric ensemble effect and the lowered d-band center after Ni alloying with Au. H 2 desorption temperature decreases from 363 K on pure Ni thin films to 302 K with increasing Au coverage to 0.6 ML. A new H 2 peak appears at around 170 K on the Au-Ni surfaces with Au coverages between 0.6 ML and 0.9 ML. This new H 2 TPD peak is assigned to H 2 desorption from the totally isolated Ni sites. With Au coverage above 1.5 ML, there is no any H 2 desorption detected. Finally, the combined surface science studies and DFT calculations provide new insights into the surface structure-activity correlation of Ni-base bimetallic surface alloys.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

PdCu Alloy Catalyst for Inhibition‐free, Low‐temperature CO Oxidation

Designing robust catalysts for low‐temperature oxidation is pertinent to the development of advanced combustion engines to meet increasingly stringent emissions limitations. Oxidation of CO, hydrocarbon, and NO pollutants over platinum‐group catalysts suffer from strong inhibition due to their competitive adsorption, while coinage metals are generally slow at activating O 2 . Through computational screening, we discovered a PdCu alloy catalyst that completely oxidizes CO below 150 °C without inhibition by NO, propylene or water. This is attributed primarily to geometric effects and the presence of CO bound to Pd sites within the Cu‐rich surface of the PdCu alloy. Here, we demonstrate that the novel PdCu catalyst can be used in tandem with a PtPd catalyst to achieve sequential, inhibition‐free, complete oxidation of CO in a two‐bed system, while also achieving 50 % NO conversion below 120 °C. Moreover, neither water nor propylene adversely affect the low temperature CO oxidation activity.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Quantifying High Temperature Corrosion

Alloys designed for high temperature service can form a variety of surface oxides or scales based on the alloy composition, service temperature, gas environment, surface deposits, etc. The most severe environments, including molten salts and liquid metals can result in significant metal loss, void formation and/or pitting. Standard and evolving practices are discussed for measuring these types of degradationincluding measuring oxide scale thickness, internal oxidation and/or metal loss, correlating them to mass change and reporting the results. Manual and automated methodologies to measure oxide thickness and metal loss are reviewed and compared in order to provide a summary of techniques and identify the best practices for quantifying a variety of materials and damage mechanisms and producing statistically meaningful results. Such techniques create datasets useful for improved understanding of corrosion degradation mechanisms, potentially better predictive models and enhanced data analytics.

Su, Yi Feng↗
DOE OSTI2024

Distribution of Tritium in the Near Surface of Candidate Structural Materials for Fusion Reactors. Type 304L Stainless Steel, Inconel, Hastelloy, Eurofer-97, Oxide Dispersion-Strengthened Alloy 14YWT

Five different candidate structural materials for fusion have undergone pure tritium gas soaking at room temperature and at 310-mbar(a) pressure. The tritium uptake on the surface and in the bulk of the alloys has been analyzed using surface leaching, chemical etching, and thermal desorption. The nickel-based alloys: Inconel-X-750 and Hastelloy-X, absorbed the least amount of total tritium compared with austenitic stainless steel AISI 304L, reduced activation ferritic-martensitic (RAFM) Eurofer-97, and advanced nanoferritic alloy 14YWT. Microstructural analyses using electron backscatter diffraction (EBSD) indicate that the number of grains and mean grain size is not a dominant factor in near surface tritium uptake. The quantity of iron dissolved in the surface oxide appears to be the major factor in encouraging tritium absorption.

O'Callaghan, James↗
DOE OSTI2021

Surface Oxidation Behavior of FeNi-based Metal Amorphous Nanocomposite (MANC) Alloys for High-Speed Motor Applications

New interest in high performance soft magnetic materials (SMMs) have been fueled by the need to lower losses at higher operating frequencies while maintaining high flux density and tunable permeability in electrical motors, transformer, and generator applications. Conventional SMMs like electrical steels and Fe-based metal amorphous nanocomposite (MANC) alloys are dominated by eddy current losses at high frequencies. Recent breakthrough in high-performance FeNi MANC have shown promise in reducing eddy current losses as compared to electrical steels. Their intrinsic adherent native surface oxide layer provides sufficient electrical insulation to reduce interlaminate eddy current losses. However, notwithstanding advances in MANCs, there exists a gap in literature on investigations of the surface oxide layer responsible for significant reduction of interlaminate eddy current losses in magnetic cores. This work presents a detailed characterization of the surface oxide, oxidation behavior, and relationship between oxide thickness and resistivity of a new FeNi MANC alloy (Fe70Ni30)80Nb4B14Si2.

Egbu, James↗
DOE OSTI2021

Effect of Li metal addition on corrosion control of Hastelloy N and stainless steel 316H in molten LiF-NaF-KF

Molten fluoride salts are used in various energy harvesting applications such as solar collectors and molten salt nuclear reactors (MSRs). Thermodynamically driven selective dissolution of alloying elements due to impurities present within the fluoride salts have been identified to be the main corrosion mechanism for structural alloys in molten fluoride salts. Impurities in these salts, during salt preparation as well as during operation, can be difficult to control. One way to prevent the selective dissolution of active alloying elements is to make the molten salt reducing by either purifying it to remove impurities or to add some reactive metal that will react with the impurities and make the salt reducing. Here this study is focused on the corrosion behaviour of Hastelloy N and 316H stainless steel in molten LiF-NaF-KF eutectic mixture (FLiNaK) at 700°C and how this behaviour changes with the addition of Li metal as a reducing impurity. Our results indicate that the active metal addition like Li can be very effective in controlling the redox behaviour of salt, which in-turn can mitigate corrosion. Even the addition of small quantities of Li metal can mitigate the selective dissolution of active alloying elements for the tested structural materials in FLiNaK. Our results also suggest that the presence of excess amounts of Li, above the minimum concentration required to react with the impurities in FLiNaK, does not have any detrimental effect in terms of formation of new intermetallic phases at the surface of the selected alloys under tested conditions.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Report Summarizing the Mechanical Properties of a Large ODS Ferritic Alloy Ingot by Forging at High Temperatures for Future Mother Tube Production

Oxide dispersion strengthened (ODS) ferritic alloys are considered the benchmark fuel cladding and core structural material in advanced nuclear energy reactors that require high-temperature strength and creep properties and resistance to radiation damage. The ODS ferritic alloys including 14YWT are produced by mechanical alloying (MA), which is time-consuming and is associated with high manufacturing costs that are not beneficial to being used in advanced nuclear energy reactors. This report summarizes the accomplishments in FY24 in the INM program for producing an ODS ferritic alloy by high-deformation, high-temperature processing of reactive and ferritic alloy powders for advanced reactor fuel cladding applications. Following four hot forging experiments, it was concluded that several significant challenges were encountered that were difficult to overcome. These challenges were related to using high annealing temperatures for pressure assisted sintering processes to produce dense microstructures, but the high annealing temperatures result in long range diffusion of Ti through the bcc Fe lattice and react with the YIG particles that are distributed on the prior surfaces of the ferritic alloy powders. In addition, it was determined that the high deformations induced by forging at high temperatures were not very effective for fracturing the reactive YIG particles into smaller particles and distributing them into the interior of the ferritic alloy powders. Spark plasma sintering was attempted for shortening the time at high temperatures, which led to full densification but the microstructure characterization results still showed that Ti atoms diffused over long distances in the bcc Fe lattice and reacted with the YIG particles. Finally, a short 30 minute high intensity ball milling experiment was conducted on blended 14WT and YIG powders for inducing severe deformations that caused the initially spherical powders of 14WT decorated with the YIG particles on the surfaces to transform to flakes and fracturing of YIG particles into smaller particles that were incorporated into the bcc Fe lattice. Two forgings were performed with the high intensity milled powders: first annealing for 20 minutes at 850ºC followed by forging and second annealing for 20 minutes at 1,100ºC followed by forging. At 850ºC, Ti atoms are effectively immobile, thus allowing for densification albeit incomplete. The deformation by forging after annealing for 20 minutes at 1,100ºC favored dynamic recrystallization processes that led to nano-size grains with very high stored energy due to high dislocation density. The corresponding VH data showed significant hardening that correlated with estimated strengthening of ~1650 MPa. This hybrid processing approach combining high intensity ball milling of powder with annealing and forging showed the most promise for producing an oxide dispersing strengthened ferritic alloy.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Removal of Bond Sodium from Full-Length Unirradiated Fermi-1 Blanket Elements and Assembly via Melt-Drain-Evaporate Process

Equipment was designed, fabricated, tested, and operated in an inert atmosphere radiological glovebox at Idaho National Laboratory to demonstrate the removal of bond sodium from full-length unirradiated Fermi-1 radial blanket elements and an entire radial blanket assembly using a Melt-Drain-Evaporate process. A series of three runs was performed with individual and multiple radial Fermi-1 blanket elements, and a fourth run was conducted with an entire Fermi-1 radial blanket assembly. After each run, the depleted uranium alloy slugs in every element slid out of its cladding, mechanically exhibiting the effectual absence of bond sodium. Quantitative and further qualitative analyses of the treated Fermi-1 material revealed the substantive, if not complete, absence of sodium metal in blanket element components. Indeed, entire columns of depleted uranium alloy slugs and associated cladding from select treated elements were separately contacted with water to react with residual sodium metal on the element surfaces, forming hydrogen gas. Samples of the resultant gas were analyzed to quantify the hydrogen concentration, which correlated to a residual sodium metal content for the treated element. Accordingly, no detectable sodium metal (<7 µg) was found on the surfaces of multiple depleted uranium alloy slugs after removal from its cladding. Detectable sodium metal, ranging from 14 to 30 µg, was found on the surfaces of one separated column of slugs and two separated full-length cladding segments. Each element originally contained ~25 g of bond sodium, resulting in quantitative sodium metal removal efficiencies of =99.9998%. The remaining separated uranium alloy slugs and cladding segments from the four runs were piece-wise immersed in alcohol while videorecording possible gas bubble formation as an additional qualitative analysis for residual sodium metal on treated surfaces, which identified the predominant absence of sodium reactivity on the balance of treated Fermi-1 blanket material. The results of this demonstration substantiate a path forward for treatment and disposal of 34 metric tons heavy metal of irradiated sodium-bonded Fermi-1 blanket material currently stored at Idaho National Laboratory.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2026

Ca Metal Batteries and Sn Anode Alloying: Resolving Misconceptions in Ca–Sn Alloy Formation

Ca metal anode suffers from surface passivation and struggles to effectively plate and strip in conventional Ca electrolytes, making the development of alloy anode for calcium metal battery essential. This work systematically and carefully evaluates the electrochemical formation and feasibility of the Sn anode and its possibility of alloying with Ca using a combination of cyclic voltammetry, scanning electron microscopy with energy-dispersive X-ray spectroscopy (SEM/EDS), X-ray diffraction (XRD), and synchrotron transmission X-ray microscopy (TXM). Electrochemical measurements and SEM/EDS analyses indicate apparent Ca alloy formation. However, detailed XRD and TXM characterization reveal substantial lithium-ion involvement when lithium metal is employed as the reference electrode, even in electrolytes with high Ca salt concentrations. These findings highlight a significant risk of misinterpretation: Although limited Ca–Sn alloying may occur, the faster kinetics of Li + can dominate the alloying process, leading to a Li-driven reactions at the Sn anode. In contrast, cells constructed with Ca metal as both reference and counter electrodes exhibit distinct redox features only during the initial cycles, followed by rapid cell failure. The high oxidation currents induce severe Ca passivation, occurring nearly concurrently with Sn dealloying. Overall, this study provides critical insight into the practical limitations and common experimental artifacts associated with Ca metal battery systems and underscores the necessity for rigorous cell design and cautious interpretation when evaluating alloy chemistry in multivalent Ca-based batteries.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Influence of copper and aluminum substitution on high-temperature oxidation of the FeCoCrNiMn “Cantor” alloy

In this study, the oxidation behavior of FeCoCrNiMn (HEA + Mn) is compared to three modified HEAs manufactured by substituting Mn with Al, Cu, or Al + Cu. Oxidation tests were conducted between 600°C and 800°C for up to 500 h in synthetic air. Substitution of Mn leads to a significant improvement in the oxidation resistance for the three modified HEAs. For FeCoCrNiCu (HEA + Cu), a local attack of a Cu-rich phase was observed, leading to the formation of CuO blisters on the surface. The FeCoCrNiAl (HEA + Al) alloy was characterized by the formation of a thin Al 2 O 3 surface layer for all temperatures. However, for the HEA + Al alloy the formation of AlN was observed after 300 h at 800°C, leading to a partial breakdown of the protective scale. FeCoCrNiCuAl (HEA + Cu + Al) by far showed the best oxidation resistance, characterized by the formation of a highly protective Al 2 O 3 scale that effectively inhibited nitrogen penetration into the metal subsurface and local attack of the Cu-rich phase.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Strain-Driven Evolution of Structural and Carrier Recombination Dynamics in Germanium

Strain engineering in group-IV semiconductors, in particular germanium (Ge), offers a promising route for advancing next-generation optoelectronic device performance. High minority carrier lifetime serves as a direct indicator of superior material quality and device efficiency. Several factors govern the minority carrier lifetime in both strained Ge and strained GeSn, such as strain level, epilayer thickness, defects, surface roughness, and Sn alloying. In this study, the impact of biaxial strain on effective minority carrier lifetimes of tensile-strained Ge (0% ..epsilon..-Ge/Al?As, 0.78% ..epsilon..-Ge/In0.115?Ga0.885?As, and 0.93% ..epsilon..-Ge/In0.16?Ga0.84?As) and compressively strained GeSn (-0.53% c-Ge0.97?Sn0.03/Al?As) epilayers, grown by molecular beam epitaxy, was experimentally investigated via the microwave-reflection photoconductive decay (..mu..-PCD) technique as a simultaneous function of thickness and strain. The structural and strain-relaxation properties were analyzed by high-resolution x-ray diffraction and Raman spectroscopy, while surface morphology analysis using atomic force microscopy provided insights into the surface roughness of strained Ge-based epilayers. Defect characterization by cross-section transmission electron microscopy revealed superior crystalline quality of ..epsilon..-Ge in one epilayer, while twin boundary formation was observed in the other. We investigated the carrier recombination dynamics in epitaxially strained Ge by extracting the bulk recombination lifetime and surface recombination velocity using the thickness-dependent minority carrier lifetime. High effective minority carrier lifetimes of approximately 60-340 ns were achieved at high strain levels with minimal dependence on the thickness of the strained Ge-based epilayers by means of the ..mu..-PCD technique. Minority carrier lifetimes in Ge-based epilayers exhibit a quadratic dependence on the biaxial strain, ranging from -0.88% (compressive) to +1.6% (tensile). The analysis of the carrier recombination dynamics in strained Ge-based heterostructures offers a pathway to designing group-IV based optoelectronic devices.

36 MATERIALS SCIENCE↗