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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
DOE OSTI2020

Elucidating the Impact of Flow on Material-Sensitive Critical Heat Flux and Boiling Heat Transfer Coefficients: An Experimental Study with Various Materials

In this work, steady-state internal flow boiling critical heat flux (CHF) experiments were carried out at 10°C inlet subcooling and atmospheric pressure (84 kPa at an altitude of about 5300 feet) with mass flux ranging from 200 to 2,000 kg/m 2 -s on seven tube materials, including the accident-tolerant fuel cladding candidate FeCrAl (C26M) alloy. At a relatively low flow rate, the sensitivity of CHF to different materials was appreciable (the average difference among the tested materials was 19% at 200 kg/m 2 -s). As the absolute CHF differences stayed constant for higher flow rates, the increased flow rate led to reduced relative CHF differences among the tested materials (average relative difference of 15% at 1,000 kg/m 2 -s). FeCrAl alloy claddings that were oxidized under simulated Light Water Reactor (LWR) conditions yielded CHF comparable to as-received FeCrAl alloy cladding, with less than 1.8% difference. Experimental CHF results imply marginal material sensitivity impacts on the departure from nucleate boiling ratio in steady-state nuclear reactor cores. Yet, for accident progression analysis, material sensitivity may hold importance, as boiling behavior variation at low mass flux is appreciable. Macroscopic material parameters (surface wettability, surface roughness, and thermal properties) do not provide a suitable explanation for observed material-sensitive CHFs. Yet, surface roughness and thermal effusivity revealed power and linear relations, respectively, to the nucleate boiling heat transfer coefficients at low mass flux. At high mass flux, material sensitivity on nucleate boiling heat transfer significantly decreased due to the increased shear stress on boiling surface overwhelming material-related boiling implications.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Ultra-high temperature testing and performance of L-PBF C103

Additive Manufacturing (AM) of refractory alloys is gaining traction as a materials processing route for components subject to extreme temperature environments. Due to the low oxidation resistance of refractory alloys, novel methods for evaluating their elevated temperature performance must be developed. In this work, a Gleeble® 3800 thermomechanical load frame was modified to evaluate the mechanical properties of laser powder bed fusion (L-PBF) consolidated niobium alloy C103 ranging from room temperature (RT) to 1400 °C. The fixturing and sample geometry were designed to accommodate Joule heating and prevent damage to the test chamber. Oxidation of the samples was minimized via testing in vacuum level of 1E-5 Torr. Ultimate tensile strength (UTS), yield strength (YS), elongation, and strain-hardening behavior were determined as a function of temperature. L-PBF C103 presented an average UTS of ∼650 MPa and over 25 % elongation at RT. Above RT, the UTS and YS dropped then leveled off from 500 °C to 1000 °C with values ranging from ∼400 MPa to ∼460 MPa, which is consistent with dynamic strain aging observed in this class of alloys. The strength rapidly declined after 1200 °C to ∼150 MPa at 1400 °C. Fractography indicated ductile fractures for the C103 at all test temperatures, and Electron Backscatter Diffraction (EBSD) analysis revealed a textured microstructure and the presence of dynamic recrystallization within the necked region of the sample tested at 1400 °C.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

Density Functional Theory Investigation of Oxidation Intermediates on Gold and Gold–Silver Surfaces

Gold and gold-silver alloys can be active and selective oxidation catalysts. Previous work has suggested that O 2 dissociation occurs at bimetallic step sites on gold-silver alloys, but the site responsible for the rest of the reaction steps has not been studied. As a first step in gaining insight into this issue, in this work we investigated the adsorption of oxygen and other oxidation intermediates on the (111) and (211) facets of gold-silver alloys using density functional theory. Oxygen and silver coverage effects were analyzed, and different model structures were compared. We also examined the energy barriers for the diffusion of atomic oxygen to gain insight into O migration and spillover. On (111) surfaces, O adsorption is much stronger at low O coverage (less than 0.22 ML), while on (211) surfaces O is strongly bound at both high and low O coverage. O diffusion across the step is faster than diffusion along the step. Ag stabilizes O, both when directly bound to it and when in an adjacent site. Ag also reduces repulsive O-O interactions at low O coverage. Our calculated reaction barriers for O-assisted CH 3 O dehydrogenation suggest that reaction is faster on steps than on terraces. Overall, our findings suggest that spillover of O from Ag-rich steps to Au-rich terraces does not occur, and that oxidation reactions on gold-silver alloys occurs on step sites. More specifically, oxidation likely occurs either on Ag-rich step sites or on Au-rich step sites that are adjacent to Ag-rich step sites.

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

Shear Punch Testing of Neutron-Irradiated HT-9 and 14YWT

Shear punch mechanical testing was performed on neutron-irradiated HT-9 and 14YWT alloys, comparing the traditional ferritic/martensitic steel with the advanced oxide dispersion strengthened nanostructured ferritic alloy. The samples were irradiated at various temperatures between 380°C and 520°C. In HT-9, on increasing the irradiation temperature, the 1% offset shear stress and maximum shear stress decreased. The advanced 14YWT alloy was less sensitive to irradiation temperature with respect to irradiation hardening. However, it still exhibited irradiation hardening at each temperature.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Distinctive Oxide Films Develop on the Surface of FeCrAl as the Environment Changes for Nuclear Fuel Cladding

The corrosion-resistant properties of IronChromium–Aluminum (FeCrAl) alloys have been known for nearly a century. Since the 1950s, they have been explored for application in the generation of nuclear power. In the last decade, the focus has been on the use of FeCrAl as cladding for uranium dioxide fuel in light water reactors (LWRs). The corrosion resistance of this alloy depends on the oxide that it can develop on the surface. In LWRs in the vicinity of 300 °C, the external surface oxide of the FeCrAl cladding could be rich in Fe under oxidizing conditions but rich in Cr under reducing conditions. If there is an accident and the cladding is exposed to superheated steam, the cladding will protect itself by developing an alpha aluminum film on the surface.

Qu, Haozheng↗
DOE OSTI2022

Corrosion resistance of high nickel alloys in solar salt at 600 °C for up to 4000 h

This study focuses on the time dependent performance of the corrosion resistance of IN625, H230 and 740H alloys in the solar salt (60 wt% NaNO3, 40 wt% KNO3, at 600 °C) for up to 4000 h. Alloy IN625 showed the lowest mass change with parabolic oxidation kinetics that tends to stabilize with exposure time. Both 740H and H230 alloys deviated from the parabolic oxidation behavior beyond the 3000 h of exposure. Alloy 740H showed the highest mass loss due to the nonuniform surface oxidation and the high chromium dissolution rate. Internal oxidation was noticed with Alloy H230 due to the high tungsten concentrations.

36 MATERIALS SCIENCE↗
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 OSTI2022

High-Temperature Tensile and Creep Test Results on Thin Wall Tube Specimens of ODS Alloys 14YWT and OFRAC

High-temperature tensile and strain rate jump (SRJ) creep tests were conducted on axial specimens fabricated from thin wall tubes of the oxide dispersion strengthened (ODS) alloys 14YWT and OFRAC. The dimensions of the 14YWT thin wall tube was 10.7 mm OD, 0.5 mm WT and 0.92 m and of the OFRAC thin wall tube was 8.5 mm OD + 0.5 mm WT and 1.78 m in length. The axial specimens fabricated from the thin wall tubes were based on a dual-gauge design with gauge dimensions of 4 mm long and 2 mm wide. The tensile tests were conducted in air at 800ºC, 900ºC and 1,000ºC and the SRJ creep tests were conducted in air at 800ºC. Two axial specimens were used in each tensile and SRJ creep tests. The results of the tensile tests showed much lower yield stress (YS) compared to ultimate tensile strength (UTS) indicative of large work hardening properties. The results showed the UTS of OFRAC was higher than that of 14YWT by ~35 MPa at 800ºC. At 900ºC, the UTS of OFRAC and 14YWT was similar at 900ºC and at 1000ºC, the UTS of 14YWT was higher than that of OFRAC by ~10 MPa. The ductility properties of OFRAC were greater than that of 14YWT with higher values of uniform elongation (UE) and total elongation (TE) at all tensile test temperatures. The creep properties of 14YWT and OFRAC were evaluated by the strain rate jump test method at 800ºC. The stress exponent (n) for creep was obtained from the SRJ test data by plotting the values of the log strain rate against the log stress, which is measured from the stress-strain curve generated during the SRJ test. The results showed the highest stress exponents of n = 19.8 and n = 35.0 were measured from the two SRJ tests on 14YWT. The stress exponent measured from one successful SRJ test on OFRAC was n = 13.3, which was lower than that of 14YWT. Nevertheless, these high values of stress exponent are consistent with ODS ferritic alloys such as 14YWT and OFRAC since they indicate dislocation-particle interactions are the dominant creep mechanism for specific ranges of temperature and stress. The results obtained from the tensile and SRJ creep tests conducted on axial specimens in this study indicate that 14YWT and OFRAC retain high strengths at temperatures up to 1,000ºC and good creep performance at 800ºC.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Effect of oxide impurities on the corrosion behavior of structural materials in molten LiF-NaF-KF

The corrosion of materials in molten fluoride salts is largely influenced by the presence of impurities in the salt. Very few studies have been done on the effect of oxide impurities on the corrosion of structural alloys in molten fluoride salts. In this study, corrosion behavior of selected alloys was studied in molten FLiNaK with the addition of different oxides such as Li 2 O, NiO, and Cr 2 O 3 . The results show that addition of oxides can lead to significant effects on this corrosion, depending on the type and amount of oxide added and the alloy being used.

14 SOLAR ENERGY↗
DOE OSTI2020

Reduction of Oxidized Pd/Ag(111) Surfaces by H 2 : Sensitivity to PdO Island Size and Dispersion

Understanding the migration of species across interfaces in bimetallic systems is key to exploiting their bifunctionality for chemical reactivity and heterogeneous catalysis. The present study demonstrates that the sizes and dispersion of oxidized Pd islands present on oxidized Ag(111) in addition to the concentration of active Pd sites have a significant influence on the rate of surface reduction by H 2 . Two distinct types of Pd oxide islands were generated for this investigation and characterized using X-ray photoelectron spectroscopy and scanning tunneling microscopy. Small, uniformly-dispersed PdO x islands (1-5 nm diameter) were created by depositing Pd onto AgO x surfaces, while larger, non-uniformly dispersed PdO x agglomerates (30-50 nm) were produced by depositing Pd on Ag(111) prior to oxidizing. Based on X-ray photoelectron spectroscopy, the small PdO x islands have a higher concentration of undercoordinated Pd atoms than the large agglomerates. Both types of PdO x are found to dramatically enhance the reduction of AgO x by H 2 at 300 K due to the ability of the PdO x to dissociate H 2 ; the pure AgO x surfaces are unreactive toward H 2 . The rate of reduction at 300 K is found to be 2-4 times larger for the AgO x surface covered by small, uniformly dispersed PdO x islands. The higher reactivity of this surface is attributed to enhanced migration of oxygen and hydrogen atoms between the PdO x and AgO x phases due to the sizes and high dispersion of the small PdO islands as well as the higher concentration of active Pd sites on the PdO x . Furthermore, the results of this study demonstrate that reactant migration between co-existing surface phases is highly sensitive to both the intrinsic chemical activity and morphological properties of the active phase (PdO x ) and reveal that these properties can be significantly influenced by the method of synthesizing the oxidized bimetallic surfaces.

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

Compatibility of Wrought Superalloys with Supercritical CO2

Supercritical CO2 (sCO2) power cycles, particularly direct-fired cycles, have the possibility of revolutionizing clean fossil energy with peak temperatures above 700 °C and wrought precipitation strengthened alloys like Haynes 282™ for structural components. At temperatures <650 °C, it would be desirable to use less expensive alloys, however, steels are known to be susceptible to carburization. Laboratory 300 bar sCO2 autoclave results were collected on a range of alloys including less expensive Ni-based alloys like 825 compared to advanced austenitic steels like alloy 709 at 600 °C. Both alloys 825 and 709 formed thin, protective Cr-rich oxides after 1,000 h. Alloy 825 also was exposed for 1,000 h in sCO2 at 800 °C and compared to a range of Ni-based alloys. Comparing alloys 625, 825, and 282, the mass gain increased with increasing alloy Ti content under these conditions. High Al superalloys did not perform significantly better under these conditions at 800 °C.

Pint, Bruce↗
DOE OSTI2024

Comparison of Mg-based liquid metal ion sources for scalable focused-ion-implantation doping of GaN

We compare the suitability of various magnesium-based liquid metal alloy ion sources (LMAISs) for scalable focused-ion-beam (FIB) implantation doping of GaN. We consider GaMg, MgSO 4 $\bullet$7H 2 O, MgZn, AlMg, and AuMgSi alloys. Although issues of oxidation (GaMg), decomposition (MgSO 4 $\bullet$7H 2 O), and excessive vapor pressure (MgZn and AlMg) were encountered, the AuMgSi alloy LMAIS operating in a Wien-filtered FIB column emits all Mg isotopes in singly and doubly charged ionization states. We discuss the operating conditions to achieve <20 nm spot size Mg FIB implantation and present Mg depth profile data from time-of-flight secondary ion mass spectrometry. We also provide insight into implantation damage and recovery based on cathodoluminescence spectroscopy before and after rapid thermal processing. Prospects for incorporating the Mg LMAIS into high-power electronic device fabrication are also discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Design of an alumina forming coating for Nb-base refractory alloys

Refractory multi-principal element alloys (RMPEAs) promise to significantly enhance gas turbine engine efficiency, but their poor oxidation performance inhibits their implementation. Alumina-forming bond coat alloys can provide oxidation protection, but discovering suitable chemistries remains a challenge. We employed a design methodology that screens for alumina-formation capability using Al activity and phase constitution predictions from CalPhaD (Thermo-Calc). Alloy down-selection from approximately 7,800 alloys in the Nb-Si-Ti-Al-Hf system was conducted via analysis of calculated thermodynamic properties with number-density topology style maps. This approach is validated by creating and testing the composition Nb 12 Si 23 Ti 24 Al 36 Hf 5 , which forms protective alumina scales up to 1400 °C and resists pesting at 800 °C. Further, the alloy has an average coefficient of thermal expansion of ~10.1 ppm/K, making it well matched to Nb-based refractory alloys. The methodology will be useful for the design of coatings for RMPEAs, enabling their implementation and significant efficiency benefits sooner.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Accelerated Cu2O Reduction by Single Pt Atoms at the Metal-Oxide Interface§

The reducibility of metal oxides, when serving as the catalyst support or the active sites themselves, plays an important role in heterogeneous catalytic reactions. Here we present an integrated experimental and theoretical study that reveals how the addition of small amounts of atomically dispersed Pt at the metal/oxide interface dramatically enhances the reducibility of a Cu2O thin film by H2. X-ray photoelectron spectroscopy (XPS) and temperature-programmed desorption (TPD) results reveal that upon oxidation, a PtCu single-atom alloy (SAA) surface is covered by a thin Cu2O film and is therefore unable to dissociate H2. Despite this, in situ studies using ambient pressure (AP) XPS reveal that the presence of a small amount of Pt under the oxide layer can, at the single-atom limit, promote the reduction of Cu2O by H2 at room temperature. We build two density functional theory based surface models to better understand these experimental findings: A Cu2O/Cu(111)-like surface oxide layer, known as the ‘29’ oxide, in which Pt is alloyed into the Cu(111) surface as well as a PtCu SAA. Our calculations suggest that the increased activity is due to the presence of atomically dispersed Pt under the surface oxide layer, which weakens the Cu-O bonds in its immediate vicinity, thus making the interface between subsurface Pt and the surface oxide a nucleation site for the formation of metallic Cu. This initial step in the reduction process results in the presence of surface Pt atoms surrounded by metallic Cu patches, and the Pt atoms become active in H2 dissociation, which consequently accelerates the reduction of the oxide layer. This work demonstrates how isolated Pt atoms at the metal/oxide interface of a Cu-based catalyst accelerate the reduction of the oxide and, therefore, helps maintain the active, reduced state of the catalyst under reaction conditions, as is required for the synthesis of methanol from CO2 hydrogenation.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Structure evolution and tin redistribution during oxidation of Zircaloy-4 at 500°C

Zirconium (Zr) alloys are widely used as fuel cladding in nuclear power reactors due to their thermal stability, mechanical durability, corrosion resistance, and low neutron absorption cross-section. However, their performance is challenged by oxidation in reactor environments, making the study of Zr alloy corrosion behavior crucial for ensuring the safety, longevity, and economic viability of nuclear power systems. While the oxidation behavior of Zr-based cladding materials has been extensively studied since the 1950s, a mechanistic understanding into the relationship between structure evolution, solute element redistribution, and properties remains elusive. Valuable insights may be obtained through advanced experimental methods, such as in-situ and high resolution microscopy techniques. Here, in this study, the oxidation behavior of Zircaloy-4 at 500 °C in O 2 is characterized using a multimodal advanced characterization approach. Using in-situ X-ray diffraction, the phase evolution from metastable to stable oxides is tracked in real time. Complementary high-resolution techniques, including electron microscopy and atom probe tomography, reveal nanoscale insights into the microstructural changes and solute redistribution across the oxide/metal interface. Nanohardness mapping across the oxide/metal interface highlights localized mechanical property variations that may be linked to changes in microstructure and crystal structure within the oxide layer. These findings offer valuable insights into the microstructure and property evolution of Zircaloy-4 during oxidation, contributing to a better understanding of microstructural changes in Zr-based alloys under oxidative environments.

APT↗
DOE OSTI2025

Impact of Hydrogen Combustion on the Oxidation-induced Degradation of Heavy-duty Diesel Engine Piston Materials

High temperature ferritic-martensitic steels are candidate materials for heavy-duty diesel engine pistons. The envisioned transition to hydrogen blended fuels is expected to alter the post-combustion atmosphere in the engines, primarily resulting in a higher water vapor content (> 20 vol%) and potentially higher exhaust gas temperatures. The oxidation resistance of existing and newly developed alloys will be a critical life-limiting mechanism under these conditions. In the present work, the oxidation behavior of candidate piston alloys was evaluated in air+10 vol.% H2O and air+30 vol.% H2O at 700°C. Thermal cyclic (1h cycle) exposures were conducted for two variants of commercial UNSS42200 ferritic-martensitic steel and two developmental alloy steels for up to 300h. The developmental alloys each have similar compositions but with one containing elevated Cu levels of 3 wt.%, A significant reduction in resistance to breakaway oxidation was observed for the commercial alloys in the higher water vapor atmosphere. Microstructural characterization (optical metallography, scanning electron microscopy and electron microprobe analysis) revealed the formation of thick Fe-rich oxides even for the high Cr (~12 wt.%) steels after an initial stage of protective oxidation with MnCr-rich spinels. The impact of the evaporation-induced loss of Cr on the time and temperature dependent compositional changes in the alloys was correlated with experimental findings. For the developmental alloys, Cu additions appear to play a role in significantly reducing oxidation kinetics in air+30 vol.% H2O at 700°C.

Pillai, Rishi [ORNL] (ORCID:0000000243688197)↗
DOE OSTI2024

Nanostructured Alumina Forming Austenitic Alloy (NAFA) Production Using Mechanical Alloying and High-Temperature Consolidation

Alumina-forming austenitic (AFA) alloys are a promising class of nuclear materials because of their high-temperature oxidation/corrosion resistance and mechanical properties. Unfortunately, these alloys are limited in use for core material applications, and they are specifically limited for use as nuclear fuel cladding because of their high Ni-transmutation and helium generation rate in-service. Improving these alloys through a fine dispersion of oxide precipitates and thus increasing the effective irradiation sink strength of the alloy system may mitigate many of the degradation phenomena expected during alloy deployment. These phenomena include high-temperature helium embrittlement and cavity swelling for lead-cooled fast reactor applications. This work effort uses combination of conventional and advanced manufacturing approaches are being used to fabricate nanostructured AFA (NAFA) materials. As the first objective of this initiative, a conventional AFA was modified using mechanical alloying and extrusion to alter the precipitation characteristics to include a fine dispersion of nanoscale oxides intended to serve as traps for irradiation-induced point defects and transmuted He within the lattice. This analysis compared the efficacy of the conventional mechanical alloying and extrusion approach with the unalloyed AFA consolidated approach using hot isostatic pressing (HIP). It was found that, although the mechanical alloying approach is successful in producing a fine distribution of oxides within the first nanostructured AFA (NAFA-1), the distribution is heterogeneous because of the mild milling parameters used to prevent cold welding of powder to the spherical milling media. The additional dispersion of oxides, coupled with a higher volume fraction of other secondary phases in the NAFA-1, produces higher alloy strengths that range up to 600°C in comparison to the unalloyed HIP AFA, thus exceeding the operating temperature of lead-cooled fast reactors. However, the strength of the NAFA-1 is lower than that of the HIP AFA at 800°C, which is presumed to be a function of increased secondary phases from the nonoptimized AFA chemistry. Future work is planned on a newly procured NAFA-2 chemistry that is more suitable for advanced reactor applications exploring new manufacturing routes.

36 MATERIALS SCIENCE↗