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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 289 records · Page 16
All sourcesNASA NTRSDOE OSTI
NASA NTRS1988

Evaluation of candidate alloys for the construction of metal flex hoses in the STS launch environment

Various vacuum jacketed cryogenic supply lines at the Shuttle launch site use convoluted flexible expansion joints. The atmosphere at the launch site has a very high salt content, and during a launch fuel combustion products include hydrochloric acid. This extremely corrosive environment has caused pitting corrosion failure in the flex hoses, which were made out of 304L stainless steel. A search was done to find a more corrosion resistant replacement material. Nineteen metal alloys were tested. Tests which were performed include electrochemical corrosion testing, accelerated corrosion testing in a salt fog chamber, long term exposure at the beach corrosion testing site, and pitting corrosion tests in ferric chloride solution. Based on the results, the most corrosion resistant alloys were found to be, in order, Hastelloy C-22, Inconel 625, Hastelloy C-276, Hastelloy C-4, and Inco Alloy G-3. Of these top five alloys, the Hastelloy C-22 stands out as being the best of the alloys tested.

Macdowell, Louis G., III↗
NASA NTRS1988

Evaluation of candidate alloys for the construction of metal flex hoses in the STS launch environment

Various vacuum jacketed cryogenic supply lines at the Shuttle launch site use convoluted flexible expansion joints. The atmosphere at the launch site has a very high salt content, and during a launch, fuel combustion products include hydrochloric acid. This extremely corrosive environment has caused pitting corrosion failure in the flex hoses, which were made of 304L stainless steel. A search was done to find a more corrosion resistant replacement material. This study focused on 19 metal alloys. Tests which were performed include electrochemical corrosion testing, accelerated corrosion testing in a salt fog chamber, long term exposure at the beach corrosion testing site, and pitting corrosion tests in ferric chloride solution. Based on the results of these tests, the most corrosion resistant alloys were found to be (in order) Hastelloy C-22, Inconel 625, Hastelloy C-276, Hastelloy C-4, and Inco Alloy G-3. Of these top five alloys, the Hastelloy C-22 stands out as being the best of those tested for this application.

Ontiveros, Cordelia↗
NASA NTRS1991

Localized corrosion of high performance metal alloys in an acid/salt environment

Various vacuum jacketed cryogenic supply lines at the Space Shuttle launch site at Kennedy Space Center use convoluted flexible expansion joints. The atmosphere at the launch site has a very high salt content, and during a launch, fuel combustion products include hydrochloric acid. This extremely corrosive environment has caused pitting corrosion failure in the thin walled 304L stainless steel flex hoses. A search was done to find a more corrosion resistant replacement material. The study focussed on 19 metal alloys. Tests which were performed include electrochemical corrosion testing, accelerated corrosion testing in a salt fog chamber, and long term exposure at a beach corrosion testing site. Based on the results of these tests, several nickel based alloys were found to have very high resistance to this corrosive environment. Also, there was excellent agreement between the electrochemical tests and the actual beach exposure tests. This suggests that electrochemical testing may be useful for narrowing the field of potential candidate alloys before subjecting samples to long term beach exposure.

Macdowell, L. G.↗
NASA NTRS1974

The effect of heat treatment and test parameters on the aqueous stress corrosion cracking of D6AC steel

The crack growth behavior of D6AC steel as a function of stress intensity, stress and corrosion history and test technique, under sustained load in natural seawater, 3.3 percent NaCl solution, distilled water, and high humidity air was investigated. Reported investigations of D6AC were considered with emphasis on thermal treatment, specimen configuration, fracture toughness, crack-growth rates, initiation period, threshold, and the extension of corrosion fatigue data to sustained load conditions. Stress history effects were found to be most important in that they controlled incubation period, initial crack growth rates, and apparent threshold.

Gilbreath, W. P.↗
DOE OSTI2025

Low-Cost Sulfur Thermal Storage for Solar Industrial Process Heat Applications

Industrial process heat (IPH) is one of the largest energy demands in U.S., representing about 10% of all domestic energy consumption. Fuel costs to generate this industrial process heat are generally a top three cost for industry, a major component in American manufacturing competitiveness. Roughly 60% of US IPH demand (about 6,500 TBtu annually) falls in the medium-temperature range of 100–250 °C. While concentrated solar thermal (CST) technologies can provide a cost-effective source of heat in this temperature range, solar intermittency limits their adoption in industries that operate 24/7. Element 16 Technologies, Inc. developed a low-cost sulfur thermal energy storage (TES) technology to bridge this gap by capturing excess solar heat during the day and dispatching it reliably during non-solar hours. The core innovation is the use of sulfur, an abundant, industrial waste byproduct that costs ten times less than molten salt used in commercial TES systems. The overall goal of the project was to advance the design and development of molten sulfur TES to a manufacturing-relevant prototype stage for solar industrial process heat applications, while establishing and validating a realistic pathway to commercial success. Key tasks included corrosion and mechanical durability testing to identify cost-effective materials, design investigations using physics-based simulation tools, techno-economic evaluations of system lifetime costs, and pilot-scale testing for performance verification. Corrosion testing of steel alloys under cyclic molten sulfur conditions showed that austenitic stainless steels in the 300 series performed particularly well, with no structural degradation of welds or joints. Thermal cyclic testing of pilot sulfur TES units up to 1.5 MWh quantified charge/discharge rates, heat losses, round-trip efficiency and validated the system's capability to operate effectively under intermittent charging conditions. A techno-economic model, informed by sulfur TES performance model validated using pilot test data, showed that hybrid solar+sulfur TES+NG boiler systems are economically competitive with incumbent natural gas boilers for multiple locations in the southwest US. In summary, this project established molten sulfur TES as a technically viable pathway to improve economic competitiveness of American manufacturing by lowering the cost of solar industrial process heat.

14 SOLAR ENERGY↗
NASA NTRS1977

The stress corrosion resistance and the cryogenic temperature mechanical properties of annealed Nitronic 60 bar material

Ambient and cryogenic temperature mechanical properties and the ambient temperature stress corrosion properties of annealed, straightened, and centerless ground Nitronic 60 stainless steel alloy bar material are presented. The mechanical properties of longitudinal specimens were evaluated at test temperatures from ambient to liquid hydrogen. The tensile test data indicated increasing strength with decreasing temperature to -196 C. Below liquid nitrogen temperature the smooth tensile and notched tensile strengths decreased slightly while the elongation and reduction of area decreased drastically. The Charpy V-notched impact energy decreased steadily with decreasing test temperature. Stress corrosion tests were performed on longitudinal tensile specimens and transverse C-ring specimens exposed to: alternate immersion in a 3.5% NaCl bath; humidity cabinet; and a 5% salt spray atmosphere. The longitudinal tensile specimens experienced no corrosive attack. Approximately 3/4 of the transverse C-rings exposed to alternate immersion and to salt spray experienced a pitting attack on the top and bottom ends. Additional stress corrosion tests were performed on transverse tensile specimens. No failures occurred in the 90% stressed specimens exposed for 90 days in the alternate immersion and salt spray environments

Montano, J. W. L.↗
NASA NTRS1979

Tests of NASA ceramic thermal barrier coating for gas-turbine engines

A two-layer thermal barrier coating system with a bond coating of nickel-chromium-aluminum-yttrium and a ceramic coating of yttria-stabilized zirconia was tested for corrosion protection, thermal protection and durability. Full-scale gas-turbine engine tests demonstrated that this coating eliminated burning, melting, and warping of uncoated parts. During cyclic corrosion resistance tests made in marine diesel fuel products of combustion in a burner rig, the ceramic cracked on some specimens. Metallographic examination showed no base metal deterioration.

Liebert, C. H.↗
DOE OSTI2025

Corrosion and Mechanical Durability Testing in High Temperature Molten Sulfur (CRADA Final Report)

The overall goal of the project is to explore and identify suitable candidate materials for high-temperature molten sulfur thermal energy storage (TES) operating up to a maximum temperature of 400°C–420°C for industrial process heat applications. A detailed corrosion and strength analysis of coupons subjected to long-term thermal testing in molten sulfur will be conducted to characterize the fundamental corrosion mechanism, corrosion rates, and mechanical durability. The results from the project contribute to the engineering design of sulfur TES systems with desired longevity and lower construction and maintenance costs. The research outcome benefits the TES research and development community by providing detailed corrosion and degradation information for more effective engineering design of the molten sulfur TES containment. It improves the diversity and reliability of the renewable technologies available for the U.S. industries and U.S. power grid.

14 SOLAR ENERGY↗
NASA NTRS1929

Corrosion Embrittlement of Duralumin V : Results of Weather-Exposure Tests

In a series of weather exposure tests of sheet duralumin, upon which accelerated corrosion tests in the laboratory by the wet-and-dry corrosion method in a sodium chloride solution has already been carried out, a close parallelism between the results of the two kinds of tests was found to exist. The exposure tests showed that the lack of permanence of sheet duralumin is largely, if not entirely, due to corrosion. A corrosion attack of an intercrystalline nature is very largely responsible for the degree of embrittlement produced. The rate of embrittlement was greatly accelerated by a marine atmosphere and by the tropical climate. Variations in corrosion and embrittlement are noted in relation to heat treatment, cold working, and types of protective coatings.

Rawdon, Henry S↗
DOE OSTI2022

Relationship Between the Marginal Probability of Failure for a CPP Test and the Recommended Corrosion Control Requirements for Hanford Double Shell Waste Tanks

The Hanford Site in Washington State currently stores millions of gallons of radioactive waste in underground, carbon steel, double shell tanks (DSTs) that were constructed between 1968 and 1986. A chemistry control and monitoring program has been established mitigate corrosion in order to extend the service life for the DSTs. The current waste temperatures in the DSTs are at historical lows (i.e., typically less than 50 °C). The previous chemistry control requirements were determined for conditions at temperatures significantly higher. SRNL undertook a statistically based investigation of the role of nitrate and halide ion (i.e., chloride and fluoride) induced pitting corrosion. The objective was to develop a comprehensive waste chemistry envelope for the simultaneous minimization of the pitting and SCC risks caused by halide and nitrate ions at the lower temperature conditions. On the basis of these tests, new chemistry control requirements were proposed and have since been implemented for pitting corrosion control.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS1985

Cast iron-base alloy for cylinder/regenerator housing

NASACC-1 is a castable iron-base alloy designed to replace the costly and strategic cobalt-base X-40 alloy used in the automotive Stirling engine cylinder/generator housing. Over 40 alloy compositions were evaluated using investment cast test bars for stress-rupture testing. Also, hydrogen compatibility and oxygen corrosion resistance tests were used to determine the optimal alloy. NASACC-1 alloy was characterized using elevated and room temperature tensile, creep-rupture, low cycle fatigue, heat capacity, specific heat, and thermal expansion testing. Furthermore, phase analysis was performed on samples with several heat treated conditions. The properties are very encouraging. NASACC-1 alloy shows stress-rupture and low cycle fatigue properties equivalent to X-40. The oxidation resistance surpassed the program goal while maintaining acceptable resistance to hydrogen exposure. The welding, brazing, and casting characteristics are excellent. Finally, the cost of NASACC-1 is significantly lower than that of X-40.

Witter, Stewart L.↗
NASA NTRS1965

Potassium corrosion studies

Potassium corrosion studies - refluxing K tests of Nb-containing alloys, refluxing K stress corrosion tests with D-43 alloy, and K compatibility tests

STRESS CORROSION↗
NASA NTRS2014

Salt Spray Test to Determine Galvanic Corrosion Levels of Electroless Nickel Connectors Mounted on an Aluminum Bracket

During preliminary vehicle design reviews, requests were made to change flight termination systems from an electroless nickel (EN) connector coating to a zinc-nickel (ZN) plating. The reason for these changes was due to a new NASA-STD-6012 corrosion requirement where connectors must meet the performance requirement of 168 hr of exposure to salt spray. The specification for class F connectors, MIL-DTL-38999, certifies the EN coating will meet a 48-hr salt spray test, whereas the ZN is certified to meet a 168-hr salt spray test. The ZN finish is a concern because Marshall Space Flight Center has no flight experience with ZN-finished connectors, and MSFC-STD-3012 indicates that zinc and zinc alloys should not be used. The purpose of this test was to run a 168-hr salt spray test to verify the electrical and mechanical integrity of the EN connectors and officially document the results. The salt spray test was conducted per ASTM B117 on several MIL-DTL-38999 flight-like connectors mounted to an aluminum 6061-T6 bracket that was alodined. The configuration, mounting techniques, electrical checks, and materials used were typical of flight and ground support equipment.

Rolin, T. D.↗
NASA NTRS1986

Testing and analysis of photovoltaic modules for electrochemical corrosion

This paper describes the testing and evaluation used to characterize the mechanisms of electrochemical corrosion of photovoltaic modules - encapsulated solar cells. Accelerated exposure testing was performed on a sample matrix of cell/encapsulant combinations, and microanalytical failure analysis was performed on selected samples to confirm the correlation between the accelerated test data and the life prediction model. A quantitative correlation between field exposure time and exposure time in the accelerated multistress tests was obtained based upon the observation that equal quantities of interelectrode charge transfer resulted in equivalent degrees of electrochemical charge.

Neff, Michael↗
DOE OSTI2023

Atmospheric Pressure Plasma Treatment of Magnesium Alloy for Enhanced Coating Adhesion and Corrosion Resistance

Atmospheric pressure plasma (AP) treatment, using an open-air jet of ionized CO 2 , N 2 , or air, was applied to AZ91D Mg alloy surfaces to investigate its effects on primer coating adhesion and corrosion resistance. The CO 2 and air AP treatments formed an O- and C-rich surface layer (Mg-O-C) consisting of agglomerated nanoparticles and pits with a depth of a few microns and increasing the surface roughness by 6–8 times compared with the reference 600 grit-finished surface. Then, three commercial primers, zinc phosphate (ZnP), chromate-containing epoxy, and MIL23377, were applied on the treated surfaces to evaluate the corrosion resistance associated with the coating adhesion. Microscopic analysis demonstrated stronger interlocking between the primer layer and the nano-/microrough Mg-O-C surface compared to the untreated (600 grit-finished) surfaces, indicating improved coating adhesion and corrosion resistance. Crosscut tests of the MIL23377 primer on the CO 2 and air AP-treated surfaces showed the highest level of adhesion, ASTM class 5B. Salt spray corrosion tests showed that after 8 days of exposure, the primer coatings on air AP-treated surfaces had corrosion areas that were more than four times smaller than that of the 600 grit-finished surface. The N 2 AP treatment showed similar adhesion enhancement. The preliminary operation expenses for AP treatment using CO 2 , N 2 , and air were estimated at USD 30.62, USD 35.45, and USD 29.75 (from an air cylinder)/USD 0.66 (from an air compressor) per m 2 , respectively.

36 MATERIALS SCIENCE↗