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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 253 records · Page 14
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Combining four-point bending and corrosion to map stress-dependent corrosion susceptibility of 316H stainless steel in FLiNaK

Understanding the effect of stress on the corrosion of steels in molten salts is important for material screening and safety assessment of molten salt reactors. We present a method that combines four-point bending with corrosion testing, enabling the mapping of corrosion susceptibility as a function of local stress from a single specimen. Guided by finite element analysis, a four-point bending setup was used to bend a 316H stainless-steel bar under controlled elastic stress during a 100-hour exposure in FLiNaK at 700 °C. Post-exposure characterization using scanning electron microscopy and energy-dispersive X-ray spectroscopy revealed a pronounced correlation between stress and corrosion. Regions under tensile stress exhibited significantly deeper attack depths and greater chromium depletion along grain boundaries, whereas compressive zones showed shallower corrosion cracks. The stress effect is attributed to stress concentration under tensile loading, which promotes chromium dissolution and crack propagation. This technique can be readily applied to other structural alloys, enabling quantitative measurement of corrosion susceptibility as a function of local stress.

316H↗
DOE OSTI2014

A Perspective on Coupled Multiscale Simulation and Validation in Nuclear Materials

The field of nuclear materials encompasses numerous opportunities to address and ultimately solve longstanding industrial problems by improving the fundamental understanding of materials through the integration of experiments with multiscale modeling and high-performance simulation. A particularly noteworthy example is an ongoing study of axial power distortions in a nuclear reactor induced by corrosion deposits, known as CRUD (Chalk River unidentified deposits). We describe how progress is being made toward achieving scientific advances and technological solutions on two fronts. Specifically, the study of thermal conductivity of CRUD phases has augmented missing data as well as revealed new mechanisms. Additionally, the development of a multiscale simulation framework shows potential for the validation of a new capability to predict the power distribution of a reactor, in effect direct evidence of technological impact. The material- and system-level challenges identified in the study of CRUD are similar to other well-known vexing problems in nuclear materials, such as irradiation accelerated corrosion, stress corrosion cracking, and void swelling; they all involve connecting materials science fundamentals at the atomistic- and mesoscales to technology challenges at the macroscale.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2020

An Updated Analysis of Clad Degradation

This report provides an analysis of the clad barrier function associated with the direct disposal of dual purpose canisters (DPCs) under hypothetical conditions in a shale repository and in an alluvial repository, including the effect of a postulated criticality event inside a disposed DPC. Should a postulated criticality event occur in a hypothetical shale repository, cladding will primarily degrade by general corrosion. Stress corrosion cracking, hydride cracking, creep failure, pitting and crevice corrosion, rod pressurization, and clad unzipping are calculated to have little impact on cladding persistence. At the higher temperature expected during a postulated criticality event in a saturated shale repository, general corrosion of cladding would be rapid - on the order of 0.034 microns/yr. A few hundred years after onset of a postulated criticality event in a shale repository complete general corrosion of fuel assembly grid spacer walls and guide tubes will likely result in settling of fuel rods upon each other. This rod consolidation should displace the water moderator and possibly terminate a postulated criticality. The primary potential degradation pathway for cladding in a hypothetical alluvial repository is localized corrosion by fluoride, which cannot occur in a shale repository. Fluoride-enhanced corrosion of cladding would be accelerated under the slightly higher (< 100°C) temperatures associated with a postulated criticality event. The impact of criticality in both cases (shale and alluvial) would be to increase the amount of failed cladding. But it would require very specialized transport pathways.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2018

Decoupling the role of stress and corrosion in the intergranular cracking of noble-metal alloys

Intergranular stress-corrosion cracking (IGSCC) is a form of environmentally induced crack propagation causing premature failure of elemental metals and alloys. It is believed to require the simultaneous presence of tensile stress and corrosion; however, the exact nature of this synergy has eluded experimental identification. For noble metal alloys such as Ag–Au, IGSCC is a consequence of dealloying corrosion, forming a nanoporous gold layer that is believed to have the ability to transmit cracks into grain boundaries in un-dealloyed parent phase via a pure mechanical process. Here using atomic-scale techniques and statistical characterizations for this alloy system, we show that the separate roles of stress and anodic dissolution can be decoupled and that the apparent synergy exists owing to rapid time-dependent morphology changes at the dealloyed layer/parent phase interface. We discuss the applicability of our findings to the IGSCC of important engineering Fe- and Ni-based alloys in critical applications.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Long-term Prediction of Spent Fuel Storage Canisters - Issues and Approaches - 18112

The considerations involved in aging management of stainless steel canisters used in dry cask storage of spent fuel are discussed in this paper in a probabilistic framework. The two important modes of degradation in the long-term performance of the casks are localized corrosion and stress corrosion cracking initiating from the external surface. These degradation modes are determined by the evolution of the electrochemical behavior and the strain rate of the stainless steel. Laboratory data suggest that Type 304L/316L stainless steels should suffer from localized corrosion and SCC under salt deposits. However, field inspection of the canisters has not indicated extensive pitting or stress corrosion cracking. This discrepancy can be understood in terms of the joint probabilities of various factors that must come together to cause these failure modes. A Bayesian network approach is suggested as the framework for modeling the probability of failure of canisters and long-term management of aging. The gaps in knowledge to conduct a Bayesian network analysis are discussed. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2018

Study on Corrosion Behavior of 7075 Aluminum Alloy with Retrogression and Reaging Using Taguchi Method

The corrosion resistance and mechanical properties of 7075 aluminum alloy are improved by retrogression and reaging (RRA) heat treatment. Due to the complex process of RRA heat treatment, a Taguchi L25 orthogonal array is designed to optimize the process parameters of RRA heat treatment. In this work, analysis of variance was performed to find out the significant heat treatment parameters. Microstructure, mechanical properties, intergranular corrosion, exfoliation corrosion and stress corrosion cracking behaviors of 7075 aluminum alloy after RRA heat treatment were investigated by tensile test, slow strain rate test, transmission electron microscope and scanning electron microscope. Results showed that the RRA treatment involving preaging at 120 °C for 16 h, retrogression at 200 °C for 8 min and reaging at 120 °C for 24 h resulted in a desired combination of corrosion resistance and mechanical properties.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Assessment of the Corrosion Risks to a Double Shell Tank During the Selective Removal of a Cesium-rich Supernate Layer - 20227

The Direct Feed Low Activity Waste (DF-LAW) activity will provide the initial feed to the Waste Treatment and Immobilization Plant at the Hanford Tank Farm facility. Feed preparation for DF-LAW will be carried out in multiple double shell waste tanks (DST) utilizing the Tank Side Cesium Removal (TSCR) process. Tank AP-106 will be an integral part of the TSCR process and hence key to the DFLAW activity. Prior to being utilized for this purpose, the Cs-137 concentration levels in the AP-106 supernate must be reduced significantly. The AP-106 re-purposing process manages normal waste tank addition procedures such that waste acceptance criteria objectives for Cs-137 removal are achieved. As this process was being developed, several concerns regarding tank integrity during and after repurposing of Tank AP-106, and the associated tanks (i.e., AP-102, AN-101, and AP-108), were addressed. The potential corrosion degradation mechanisms identified based on process knowledge included: general and pitting corrosion, caustic stress corrosion cracking, concentration cell corrosion, and microbiologically induced corrosion (MIC). A systematic approach was undertaken to assess the risk of corrosion during the AP-106 re-purposing process. The assessment considered the initial and present condition of the tank, the service history of the tank, the environmental conditions created in each tank during each stage of the process, process timing, and corrosion testing and modeling that approximated tank conditions. Based on this information, recommendations were provided to minimize the exposure of the tank to corrosive conditions. These recommendations included time limits for each stage of the process, staging of corrosion inhibitor solutions should process delays occur, and waste sampling with potential chemistry adjustments at defined steps in the process. Additionally, recommendations for post-process supernate chemistry adjustments and tank inspections were put forth. The greatest risk for this process occurs during the manipulation of large quantities of Columbia River water (i.e., greater than 450,000 gallons) within AP-106, the associated tanks and the supporting infrastructure (i.e., transfer line piping). This risk becomes more pronounced if there is a process upset and the tank walls remain exposed to a corrosive condition longer than intended. As long as the river water is blended into the supernate in a timely fashion, and the waste is adjusted appropriately with corrosion inhibitors, corrosion may be minimized and the final condition of the supernate in AP-106 and the associated tanks is expected to be in compliance with corrosion chemistry requirements. Contingency plans will be made to minimize the impact of a process upset. (authors)

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DOE OSTI2015

Summary. “Materials Challenges in Nuclear Energy,” S.J. Zinkle, 2013

Nuclear energy continues to grow in abundance and importance. It offers a future electric grid based entirely off of green energy, and it has numerous applications. Nuclear power has capabilities to desalinate water, deliver process heat or steam, affordably crack hydrogen from water, and extract unconventional fossil fuel sources. Current light water reactors demonstrate high reliability under normal operating conditions. Researchers have shown significant interest and investigating how to extend reactor lifespans and into other possible reactor designs. Further understanding of mechanisms responsible for corrosion and stress corrosion cracking, radiation hardening and degradation, and nuclear fuels innovations can lead to safer, more reliable, and cost-effective water-cooled nuclear reactors for electricity production.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2015

Hanford double-shell tank testing program - 15341

The corrosion testing program and Hanford regularly tests waste chemistries to analyze threats and develop new corrosion chemistry guidelines. Over the past few years, the focus of testing has been on the threat of leaked wastes in Tank 241-AY-102 (AY-102). From the tests conducted to date, it appears that the potential waste compositions in the annulus of tank AY-102 do not show a propensity for localized corrosion or stress corrosion cracking. The threat of exterior corrosion from the liquid and moisture in the leak detection pit (LDP) is a potential concern that will continue to be evaluated in the coming year. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2016

Progress of GE development of accident tolerant fuel FeCrAl cladding

The Accident Tolerant Fuel (ATF) concept proposed by General Electric (GE) utilizes a FeCrAl alloy and current uranium dioxide (UO{sub 2}) fuel pellets, resulting in a fuel assembly that leverages the performance of existing LWR fuel assembly designs and infrastructure with improved accident tolerance. The focus of this paper is to report on the maturity of the concept and the overall feasibility on the use of ferritic FeCrAl alloys as cladding for nuclear fuel in commercial light water reactors. The following aspects are reviewed: mechanical properties, corrosion performance, stress corrosion cracking, fabrication assessments and performance evaluation. The results show that FeCrAl alloy clad fuel rods (with UO{sub 2} fuel) have reasonably demonstrated capabilities to meet or exceed current fuel design technical requirements while providing increased safety benefit during design basis events and severe accident conditions. Initial characterization of the materials, in particular APMT (the current leading FeCrAl alloy candidate whose composition is Fe + 22Cr + 5Al + 3Mo) indicates excellent operational and accident condition performance in both PWR and BWR environments. Challenges on the neutron economy and tritium release have a reasonable path to mitigation. The fabrication processes for the FeCrAl/UO{sub 2} system appears to be very similar to current LWR fuel fabrication processes (pilgering/extruding, heat treatments, welding, NDE techniques, etc.) which are mature and well understood. No issues are anticipated complying with current nuclear industry quality and performance standards.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

Refinement of Salt Dissolution Inhibitor Requirements (Final Report)

At Savannah River Site (SRS), High-Level Waste is stored in below-grade carbon steel tanks. This waste in part consists of sludge, salt cake, and/or supernate. Preparation of this waste for future processing involves dissolution of the salt cake layer. The salt dissolution process can create conditions that leave the carbon steel tanks susceptible to localized corrosion. The salt to be dissolved contains high concentrations of nitrate, that once released, create an environment that may be conducive to pitting corrosion and/or stress corrosion cracking (SCC) of carbon steel. The salt dissolution process also liberates interstitial liquid trapped between the salt crystals. This liquid is initially high in nitrite and hydroxide concentration. High pH and greater ratios of nitrite to nitrate act as inhibitors to minimize corrosion of carbon steel in high nitrate environments. However, as dissolution proceeds, the concentration of nitrate will increase, while the hydroxide and nitrite concentration of the interstitial liquid will deplete and become insufficient to prevent the onset of corrosion attack. Tank blending and addition of inhibitors are used to ensure adequate concentrations of hydroxide and nitrite. However, this is not desirable during salt dissolution as it can reduce process efficiency and increase the amount of waste that needs processing. It has been proposed that these corrosion control limits be revisited to evaluate the corrosion susceptibility of carbon steel in environments that more closely resemble current operating conditions at SRS. An experimental matrix was designed to evaluate the use of the pitting factor for supernate chemistries characteristic to SRS, particularly during the salt dissolution process. Two electrochemical methods were identified to determine the susceptibility of A537 and A285 low-carbon steels to pitting corrosion with this chemistry envelope at temperatures up to 75 °C. The predominant electrochemical test method was Cyclic Potentiodynamic Polarization (CPP) studies. Through CPP, the pitting factor was used, based on Hanford Site corrosion studies, to accurately identify pitting susceptibility within the compositional range studied with some conservatism. Additionally, sulfate was determined to have no statistically significant influence, at concentrations up to 0.6 M, on pitting behavior in more concentrated solutions where other aggressive species govern pitting susceptibility. Where CPP was inconclusive, Modified ASTM G192 was successfully used to evaluate pitting susceptibility conditions and allowed for a pass/fail result to be determined. In all cases, the pitting factor was determined to be applicable to the simulants tested, with this metric accurately predicting incidences in which pitting occurred. Based upon the findings in this work, a pitting factor of 1.2 is being proposed to build in a safety factor and remain consistent with the Hanford Site approach. Additionally, a minimum pH limit of 12 is proposed to ensure carbon steel passivity and localized corrosion the primary degradation mechanism. Susceptibility to SCC was evaluated using a reduced matrix of tests at 75 °C. No failures due SCC were observed at open circuit. In addition, tests polarized anodically by 200 mV only resulted in failures for trials with pitting factors less than 0.86. However, a test with a passing condition based upon the pitting factor metric (pitting factor = 1.40) did exhibit a failure with an applied potential of +300 mV vs. OCP. This result is contrary to the prediction based upon the pitting factor, however, a polarization of 300 mV, or even 200 mV, from open circuit is substantial. The relationship between these testing parameters and service environment/conditions and the desired level of conservatism in the metric should be further evaluated in the determination of the significance of this result. While the pitting factor accurately predicted susceptibility to SCC at temperatures up to 75 °C and with positive overpotentials up to 200 mV, the relatively small sample matrix and failure of a passing pitting factor with a 300 mV polarization resulted in an inconclusive determination of whether the pitting factor may be used for predicting susceptibility to SCC at temperatures between 50 °C and 75 °C. As such, additional testing is recommended to evaluate the validity of the pitting factor for SCC susceptibility prediction at temperatures between 50 °C and 75 °C.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Slow Strain Rate Testing of A537 Tank Wall Material

At Savannah River Site (SRS), High-Level Waste is stored in below-grade carbon steel tanks. This waste in part consists of sludge, salt cake, and/or supernate. Preparation of this waste for future processing involves dissolution of the salt cake layer. The salt dissolution process can create conditions that leave the carbon steel tanks susceptible to localized corrosion. The salt to be dissolved contains high concentrations of nitrate, that once released, create an environment that may be conducive to pitting corrosion and/or stress corrosion cracking (SCC) of carbon steel. The salt dissolution process also liberates interstitial liquid trapped between the salt crystals. This liquid is initially high in nitrite and hydroxide concentration. High pH and greater ratios of nitrite to nitrate act as inhibitors to minimize corrosion of carbon steel in high nitrate environments. However, as dissolution proceeds, the concentration of nitrate will increase, while the hydroxide and nitrite concentration of the interstitial liquid will deplete and become insufficient to prevent the onset of corrosion attack. Tank blending and the addition of inhibitors are used to ensure adequate concentrations of hydroxide and nitrite. However, this is not desirable during salt dissolution as it can reduce process efficiency and increase the amount of waste that needs processing. This testing program was designed to examine the risk of SCC associated with utilizing the pitting factor (PF) and nitrite/nitrate (NO 2 - /NO 3 - ) ratio limits for handling dissolved salt solutions at an elevated temperature in the carbon steel waste tanks. The previously identified limits are a PF of 1.2 and an NO 2 - /NO 3 - ratio of 0.15. The results indicate that as long as the NO 2 - /NO 3 - ratio exceeds 0.1 and the PF is above approximately 0.8, there is a discernible safety margin between the open circuit potential (OCP) and the critical cracking potential (CCP) observed during applied potential testing. However, this margin, defined by the difference between the OCP and CCP, is relatively narrow, ranging from 0.1 to 0.25 volts. This small margin raises concerns about potential shifts in OCP during waste retrieval operations, which could inadvertently increase the risk of SCC if the OCP approaches or exceeds the CCP. These results confirm that dissolved salt solutions provide a potent chemistry that, under certain conditions, makes carbon steel susceptible to SCC. The next question to consider is the influence these results have on decisions for storage and retrieval of waste from the tanks. For Type III/IIIA waste tanks, the risk of SCC remains very low. First, and most importantly, the post-weld stress relief of the tanks has reduced the residual stress near the welds. Thus, without the stress component, SCC risk is minimized. The material of construction (A537 Carbon steel) for the Type III/IIIA tanks is superior to the steel in its resistance to SCC than the steel that was utilized for the Type I, II, and IV tanks (A285 carbon steel). From a chemistry control standpoint for a Type III/IIIA tank directly involved with handling dissolved salt solutions, the PF and NO 2 - /NO 3 - ratio limits may be utilized wherein chemistry control provides an extra layer of defense against SCC. Chemistry control for a Type III/IIIA tank minimizes the risk for a tank that may receive the dissolved salt solution, particularly if that tank is a Type I, II, or IV waste tank. On the other hand, if the dissolved salt solution is handled by a Type I, II, or IV waste tank the risk of SCC is real. The potent chemistry, absence of stress relief, and inferior material result in a condition that is conducive to cracking. Efforts should be made to either avoid transferring waste that may not meet the PF and NO 2 - /NO 3 - ratio criteria to one of these tanks or if it is unavoidable, take measures to minimize the consequences of a leak. As shown by these tests, even if the PF and NO 2 - /NO 3 - ratio criteria are met, there is a risk that the tank potential may be disturbed in the positive direction and the risk of SCC increase.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗