SEARCH · Search NASA

Results for “corrosion resistant material”

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.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 307 records · Page 17

All sources NASA NTRS DOE OSTI

DOE OSTI2021

Thermal Evaluation of the SAVY-4000 1 Quart Container at High Heat Loads

The SAVY-4000 Safety Analysis Report (SAR) was published in 2013 which established the design life of the container series through physical testing that meets applicable requirements from DOE M 441.1-1, Nuclear Material Packaging Manual. One critical requirement in DOE M 441.1-1 is to set a maximum heat load for the entire series to ensure that throughout the lifetime of the container, each of the components still performs within manufacture specifications. The original maximum decay heat limit has been defined within the SAVY-4000 SAR, which was accomplished by completing a series of tests that heat loaded the SAVY-4000 series and measured the steady state temperature and graded it against manufacture specifications. The container series is comprised of a corrosion resistant 316L stainless steel containment boundary, ceramic composite filter for the prevention of radiological particulate release and a chemically stable O-ring made of Viton ® . Currently, the SAVY 4000 maximum decay heat load is set at 25 Watts and the heat load expected during normal handling and storage is considered sufficient that the SAVY 4000 container requirements will not be the limiting factor for storage of most common material in use at TA-55, e.g. weapons grade oxide, americium, Pu-238 oxide and encapsulated heat sources. The SAVY 4000 lifetime was originally set as 5 years within the SAVY-4000 SAR, but in July 2019 the lifetime was extended to 15 years through a technical basis justification approved by the Department of Energy (DOE) Los Alamos Field Office. The 25 Watt limit applies to all SAVY 4000 container sizes; 1-quart, 2-quart, 3-quart, 5-quart, 8-quart, 12-quart, 5-gallon, and 10-gallon.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2024

Advanced Coating Compositions and Microstructures to Improve Uptime and Operational Flexibility in Cyclic, Low-Load Thermal Utility Plants

GE, the University of Tennessee, and Oak Ridge National Laboratory collaborated from 2020 to 2023 developing two key technologies for improving the viability of fuel switching and load following in thermal utility plants: a) cost-effective weld overlay compositions for boiler tubing b) cathodic arc coatings that deliver improvements in both erosion resistance and oxidation resistance in high temperature steam for HP turbine blades The team worked through a robust, logical project map to de-risk these two technologies and advance them from TRL 3 to TRL 6. For the cost-effective weld overlay, the team developed a ferritic filler material which was fabricated at a vendor for 18% the average market cost of Inconel 625 wire, had a corrosion rate 3x lower in conditions simulating a biomass-fired superheater and 10x lower in conditions simulating a coal-fired superheater, and was fabricated into prototype overlaid tubing that passed ASME requirements including transverse bending, dye penetrant inspection, and ASTM G-76 evaluation. For the cathodic arc coatings applied to steam turbine blades, the team developed a novel composition that was successfully transferred to a qualified vendor. The vendor was able to produce coated prototypes with 4x the as-deposited erosion resistance and 10.4x the post-steam-exposure erosion resistance of the TiN coating the vendor currently applies on GE steam turbine components, without significantly increasing process cost. These coated prototypes also passed a GE inspection and showed favorable performance in high temperature erosion, nanoindentation, sliding wear, scratch adhesion, and high cycle fatigue testing. If successfully deployed by GE, it is anticipated that the technologies will enable the following: • 25%-50% increase in time between outages for both boilers and HP turbines. • 50% decrease in cost for weld overlay on a per foot basis relative to todays NiCr alloys. • Adequate oxidation resistance and erosion for HP turbine inlet steam at >620°C and >220 bar. • No need for changes in component supply chain or any notable Capital Expenditures. 5 Decreasing component cost, increasing performance, and extending time between outages represent direct value propositions to GE and their customers. For the American consumer, these objectives translate into increased grid reliability (fewer unexpected outages), decreased Levelized Cost of Electricity, and improved environmental health (low-loading/load following to accelerate penetration of renewables). The results also have implications for wear resistant tooling, wire arc additive manufacturing, more durable components for syngas cleanup, and deployment of more efficient thermochemical pathways for carbon negative fuel production

09 BIOMASS FUELS↗

DOE OSTI2026

Degradation science: Integrating modeling and experiments to predict localized corrosion processes (Annual Progress Report)

Additively manufactured (AM) eutectic high-entropy alloys (EHEAs), such as nano-lamellar AlCoCrFeNi 2.1 , have excellent strength, ductility, and wear resistance even at elevated temperatures, but their corrosion behavior in aggressive acids at different length scales remain poorly understood. This work investigates the corrosion behavior of laser powder bed–fused (L-PBF) AlCoCrFeNi 2.1 as a function of annealing temperatures, probing degradation mechanisms from nanoscopic to macroscopic length scales. The alloy is dual phase consisting of a ductile FCC L1 2 phase and a high-strength BCC B2 phase. Rapid solidification during L-PBF produces a far-from-equilibrium nano-lamellar structure with nearly homogeneous elemental distribution, which tends to evolve upon annealing toward Cr/Co/Fe-enriched FCC and Al/Ni-enriched B2. Three conditions were studied: as-printed, 600 °C/5 h, and 1000 °C/1 h, over which B2 lamellae coarsen, lamellar spacing increases, and elemental segregation becomes more prominent. Microstructure and chemistry were characterized by scanning electron microscopy (SEM) and energy-dispersive spectroscopy (EDS), while in-situ electrochemical atomic force microscopy (EC-AFM) was used to link early (<5 h) local dissolution to microstructure after exposure in sulfuric acid. EC-AFM highlights preferential dissolution of the BCC/B2 phase where the surrounding matrix is Cr-depleted and directly quantifies the dissolution rates within individual phases, tracks the transition from early nano-scale attack to partial repassivation, to correlate height differences with current and impedance responses. To monitor longer-term behavior (up to 96 h), ex-situ AFM, SEM, and confocal imaging were combined with conventional bulk electrochemical tests, bridging nanoscale observations to micro/meso-scale damage morphologies. At the meso-scale, the deepest dissolution channels align with the build-direction lamellae and melt-pool boundaries, indicating that printing directionality guides the propagation of these localized corrosion sites. Annealing modifies corrosion by restructuring BCC/FCC phase fractions, lamellar spacing, and Cr/Al segregation, thereby changing the cathode/anode ratio and passive film stability. The results clarify how as-printed and annealed nano-lamellar architectures differ in their susceptibility to selective dissolution; how elemental segregation competes with residual stresses along the build direction. With these insights, future work will use CALPHAD-guided alloy modification to stabilize higher Cr contents in the B2 phase while retaining a dominant FCC+B2/BCC microstructure, with the goal of designing mechanically robust, corrosion-resistant EHEAs for safety-critical applications to leverage the LLNL’s broader national and global security mission.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Photoluminescence in Tagging: A Glowing Review

This literature review explores the options of using photoluminescence for tagging uranium fuel and zirconium cladding in order to easily and quickly associate interdicted material to its facility of origin or pathway after loss of institutional control. Photoluminescence is the spontaneous emission of radiation by a substance when excited by interaction with light. The source of photoluminescence can be from organic, inorganic, and organometallic compounds. Each luminophore, or compound responsible for luminescent properties, has individual strengths and weaknesses, depending on the intended use. Many factors can affect the brightness, lifetime, color, and detectability of luminophores, such as humidity, temperature, oxygen availability, noise from radiation–induced luminescence, and the presence of quenching substances like iron. Application of luminescent compound to the surface of an item can be done using paint, dye, thin film, thick film, or electrochemical coating. Several of the application techniques may have secondary functions such as corrosion resistance and detection, heat resistance, protective properties, and more. When considering cladding, there are various successful studies on the application of luminescent coatings on zirconium. However, significant research will be necessary to explore which luminophore and which application technique would best fit the intended use. In order to proceed with this research, a baseline of the natural luminescence of the intended base material (nuclear fuel or cladding) is necessary. While there may be issues with background noise, quenching from the environment, quenching from the substrate, signal to noise weakness, etc. the multitude of options may make photoluminescent tagging an option. In summary, this review has demonstrated that photoluminescence is a potential option to tag nuclear fuel and cladding, but additional paper–studies, testing, and research is required to understand the compatibility of luminescent tags in nuclear reactor environments, manufacturability, and detectability.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

Multiscale Modeling of Corrosion and Oxidation Performance and Their Impact on High-temperature Fatigue of Automotive Exhaust Manifold Components

The persistent need to reducing automobile emissions has led to the wide adoption of turbocharger technology and engine downsizing, which results in a substantial raise in exhaust temperature, reaching as high as 950°C. Therefore, the material selection for exhaust manifolds and turbocharger housings becomes significantly challenging. The successful development of the multiscale models on oxidation and corrosion performance, and their impact on high-temperature fatigue will enable the acceleration of new, high-performance, heat-resistant alloy solutions and the reduction of time and cost in achieving a durable design. In this project, we developed and validated multiscale models that can accurately predict the corrosion and oxidation performance and their impact on high-temperature fatigue of high-temperature automotive exhaust manifold components. The capability of accurately predicting the corrosion/oxidation-fatigue damage can signiﬁcantly reduce the time and cost of achieving a durable design. The models were used to guide the development of new high thermomechanical fatigue (TMF) performance alloys.

Li, Mei↗

DOE OSTI2021

A percolation theory for designing corrosion-resistant alloys

Iron-chromium and nickel-chromium binary alloys containing sufficient quantities of chromium serve as the prototypical corrosion-resistant metals owing to the presence of a nanometre-thick protective passive oxide film. Should this film be compromised by a scratch or abrasive wear, it reforms with little accompanying metal dissolution, a key criterion for good passive behaviour. This is a principal reason that stainless steels and other chromium-containing alloys are used in critical applications ranging from biomedical implants to nuclear reactor components. Unravelling the compositional dependence of this electrochemical behaviour is a long-standing unanswered question in corrosion science. Herein, we develop a percolation theory of alloy passivation based on two-dimensional to three-dimensional crossover effects that accounts for selective dissolution and the quantity of metal dissolved during the initial stage of passive film formation. We validate this theory both experimentally and by kinetic Monte Carlo simulation. Our results reveal a path forward for the design of corrosion-resistant metallic alloys.

36 MATERIALS SCIENCE↗

DOE OSTI2023

The Effects of Silicon and Niobium Concentration on the Solidification Behavior and Microstructure of Cast Monel Alloys

Cast Monel alloys are used in applications requiring a combination of good mechanical properties and excellent resistance to corrosion. Despite prevalent industrial use, relatively few studies have been conducted to investigate the relationships between composition, solidification behavior, and microstructure. Given that these alloys are used in the cast and welded conditions, these factors have a significant influence over the material properties. Here, in this work, microstructural characterization, electron probe microanalysis, X-ray diffraction, and differential scanning calorimetry were used to study how changes in Si and Nb concentrations affected the solidification path and microstructure of Monel alloys. It was found that increasing Nb concentration stabilized higher amounts of MC carbides and suppressed graphite formation during solidification. It was also found that the high nominal concentration and segregation of Si to the liquid led to the formation of Ni 31 Si 12 and other silicides via terminal eutectic reactions at the end of solidification. A pseudo-binary solidification diagram was constructed using experimental data and was applied to predict the mass fraction of solidified eutectic as a function of composition. The modeled microstructures were found to be in good agreement with experimentally measured phase fractions.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Corrosion resistant hot melt adhesive to bind metals

Hot melt adhesives (HMAs) play an important role in many industries, and their demand is expected to grow. HMAs don't require any solvents, and their application results in the formation of strong bonds with the substrate upon cooling within seconds. These properties differentiate them from liquid glues and make them preferable for practical application. Currently, commercial HMAs are used in bonding lightweight materials such as paper, polymers, and cartons, and have limited usage in areas necessitating the bonding of heavier objects like metals. Here, in this study, we report a design and testing of versatile platform comprising an ion-coordinating polymer and ionic fillers for performance optimization and understanding of structure–property relationships, enabling the rational design of HMAs with improved adhesion to metal surfaces. All-atom Molecular dynamics (MD) simulations and various characterization methods are used to elucidate the adhesion mechanism in model composite system containing polyethylene oxide mixed with chemically diverse salt particles. The maximum adhesion strength is found in composites with Al(OH) 3 and FeCl 3 fillers. Interestingly, the presence of Al(OH) 3 also provides a multifunctional anticorrosion property as measured electrochemically using the Tafel method. The discovered path to formulations with improved adhesion to metal surfaces constitutes an important step toward advancing HMAs for use in the structural and semi-structural metal work domain.

Adhesive and cohesive forces↗

DOE OSTI2020

The Long-term Storage of ILW: Building Stores with the Appropriate Environmental Controls - 20294

In the UK, containers for the storage and disposal of intermediate level radioactive waste (ILW) typically use stainless steel due to its excellent mechanical properties and corrosion resistance. The period of interim storage before a disposal facility is available, however, is longer than available engineering experience with stainless steels in relevant environmental conditions. Additionally, after disposal the ability of ILW containers to withstand further periods of exposure to the environment is expected to provide substantial benefits to the operation of a disposal facility and the safety case underpinning its closure. For these reasons, although there have been no instances of failure of stainless steels in indoor storage conditions, a focused R and D programme has been carried out to identify the environmental envelope over which the material does not significantly degrade. In this study we summarise experimental and modelling studies carried out over the last decade to build a solid mechanistic understanding of the corrosion behaviour of stainless steels in indoor atmospheric conditions. We then identify suitable environmental regimes to minimise the risk of degradation processes and explore approaches to monitoring the storage conditions to gain confidence in the long-term performance of the system. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2026

Mechanical Behavior of Neutron Irradiated Refractory Multi-Principal Element Alloys Processed via Spark Plasma Sintering

The search for advanced materials capable of withstanding the extreme conditions of Generation IV reactors is a critical area in materials science research. These reactors operate under severe environments, including high temperatures, corrosion, stress, and irradiation damage. Consequently, there is a need for innovative alloy systems to ensure the reliability and longevity of proposed Generation IV reactor components. Refractory multi-principal-element alloys (RMPEA) have emerged as a promising candidate due to their exceptional properties. These alloys, characterized by their composition of multiple principal elements in near-equiatomic ratios, exhibit superior resistance to irradiation damage, reduced void swelling, enhanced microstructural stability, and minimal irradiation-induced hardening. While initial studies on RMPEAs have shown promising results, most research has been limited to thin films, nanocrystalline microstructures, and ion irradiation, which do not accurately represent the behavior of bulk materials. To address this gap, our research focused on the neutron irradiation of bulk RMPEAs. We aim to conduct comprehensive post-irradiation examinations (PIE) of RMPEAs irradiated at the Advanced Test Reactor at Idaho National Laboratory. The RMPEAs were synthesized using spark plasma sintering (SPS) with mechanically alloyed metallurgical powder. The RMPEA specimens are a MoNbTi alloy system with additions of -Zr, and -ZrV. Furthermore, PIE consisted of mechanical testing and advanced materials characterization. The mechanical testing consisted of sub-sized tensile testing, micro- and nano- indentation. Microstructural characterization included scanning electron microscopy and transmission electron microscopy. Mechanical testing coupled with advanced microscopy techniques provides insight into phase morphology and its effects on the mechanical properties of the RMPEA specimens. The results indicate that both pristine and irradiated RMPEA specimens exhibited brittle behavior during tensile testing, which can be attributed to their heterogeneous microstructure. The SPS manufacturing process did not include any post treatment, which resulted in a heterogeneous microstructure. Energy-dispersive X-ray spectroscopy revealed the presence of intermetallic such as laves phases within the microstructure. Specifically, Ti-rich precipitates were observed in the MoNbTi specimen, while Mo-rich precipitates were found in the MoNbTiZrV specimen. Nano-hardness testing of pristine samples showed that the laves phases exhibited higher hardness values compared to the matrix phase, suggesting that precipitate hardening is likely the dominant hardening mechanism in these specimens. The results from this work will be used to build a finite element model to predict mechanical behavior of future MPEA compositions. Thus, enabling for a streamlined approach to developing novel MPEAs for the nuclear industry.

36 - MATERIALS SCIENCE↗

DOE OSTI2026

In-Situ TEM Molten Salt Corrosion

Molten salt reactors (MSRs) offer a compelling pathway for next-generation nuclear energy, with advantages in thermal efficiency, inherent safety, and flexible fuel management. Yet, halide-based molten salts introduce significant materials challenges, particularly alloy corrosion. Alloy performance in these environments ultimately depends on understanding how corrosion initiates and progresses at the nanoscale, however most existing models rely on post-exposure characterization, leaving degradation mechanisms largely inferred rather than directly observed. NiCr alloys have garnered interest in MSRs applications as the Ni-based matrix provides strength and creep resistance, while Cr content offers oxidation resistance in air. However, NiCr corrosion resistance in chloride salts has proven poor due to preferential chromium dissolution, the formation of Cr-depleted pathways, and grain-boundary attack. This work aims to directly visualize corrosion of Ni-20Cr exposed to LiCl-KCl using in-situ Transmission Electron Microscopy (TEM) to capture real-time microstructural evolution during corrosion. Experiments will be performed at ~800 °C under controlled pressure conditions while utilizing Energy-Dispersive X-ray Spectroscopy (EDS) to analyze elemental redistribution. Observation of chromium depletion fronts, associated surface restructuring, and localized chloride enrichment are expected. Ultimately, this study is expected to provide a link between microscale processes and the macroscopic degradation behaviors relevant to MSR operation in advanced reactor environments. Simultaneously, this approach enables future in-situ investigations regarding alloy composition, salt chemistry, and their influence on corrosion pathways and long-term stability.?

36 - MATERIALS SCIENCE↗

DOE OSTI2021

Sequestration and release of nitrite and nitrate in alkali-activated slag: A route toward smart corrosion control

Intercalating the corrosion inhibitive ions in hydrotalcite is a promising approach to improve the long-term efficiency of inhibitors in corrosion protection of steel in reinforced concrete. In this work, the potential of autogenously generating nitrite- and nitrate-intercalated hydrotalcite in alkali-activated slag (AAS) is investigated. The results show that the added nitrite and nitrate ions are preferably uptaken in the interlayer structure of hydrotalcite in AAS, and the sequestered nitrite and nitrate are released upon chloride exposure in seawater and NaCl solution. The incorporation of nitrite and nitrate has little detrimental effects on the chloride binding capacity of AAS but slightly enhances the chloride ingress due to the pore coarsening effect. Similar to ordinary Portland cement (OPC), AAS is more permeable to the chloride in seawater than NaCl solution. However, unlike the release of bound chloride contributed by ettringite formation in seawater-exposed OPC, the enhanced chloride ingress in seawater-exposed AAS is primarily attributed to the aggravated pH reduction at the exposure front due to brucite formation. This study contributes to the design of alkali-activated binders with a smart inhibitor releasing ability for mitigating corrosion of steel in concrete.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Probing layered structure of Inconel 625 coatings prepared by magnetron sputtering

Coating/substrate interface and oxide layers present in Inconel 625 film may cause significant impacts on its corrosion behavior. However, layered structure of Inconel 625 coatings remains poorly understood due to its requirement of high spatial resolution. Here we have applied X-ray reflectometry (XRR) to probe the layered structure of magnetron-sputtered Inconel 625 film with atomic spatial resolution. Our results indicate that there exists a 2 nm thick Cr-rich Inconel sublayer underneath the principal film. On top of the principal film, it is found a 2 nm thick oxide layer mainly consisting of NiO. In addition, we detected ~2 Å contamination layer on the sapphire substrate, although argon ion sputter cleaning had been applied to the substrate prior to deposition. By comparing the coatings with different deposition time, we observed that the thickness of principal Inconel 625 layer grows linearly with deposition time, with all other layers remaining constant. Our findings provide insight into the layered structures of Inconel 625 coatings with atomic-scale spatial resolution, and provide directions for future efforts that aim to improve the corrosion resistance of Inconel 625 coatings.

14 SOLAR ENERGY↗

DOE OSTI2021

Peening Techniques for Surface Modification: Processes, Properties, and Applications

Surface modification methods have been applied to metals and alloys to change the surface integrity, obtain superior mechanical properties, and improve service life irrespective of the field of application. In this review paper, current state-of-the-art of peening techniques are demonstrated. More specifically, classical and advanced shot peening (SP), ultrasonic impact peening (UIP), and laser shock peening (LSP) have been discussed. The effect of these techniques on mechanical properties, such as hardness, wear resistance, fatigue life, surface roughness, and corrosion resistance of various metals and alloys, are discussed. This study also reports the comparisons, advantages, challenges, and potential applications of these processes.

microstructure↗

DOE OSTI2023

Microstructure and corrosion of CrFeMnV multi-principal element alloy

In this study, a multi-principal element alloy consisting of equiatomic concentrations of Cr, Fe, Mn, and V was produced by arc melting. The combination of X-ray diffraction, scanning electron microscopy and energy-dispersive X-ray spectroscopy indicated that the CrFeMnV MPEA was comprised of a BCC matrix with a dispersion of a secondary phase. Cyclic potentiodynamic polarization tests in 0.6M NaCl revealed high corrosion resistance – superior to that of stainless steel 304L, as evident from high breakdown and repassivation potentials. X-ray photoelectron spectroscopy and time-of-flight secondary ion mass spectrometry provided insight into the formed multi-layer surface film after constant immersion and potentiostatic conditioning.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Intergranular precipitation-enhanced wetting and phase transformation in an Al0.4CoCrFeNi high-entropy alloy exposed to lead-bismuth eutectic

We report after exposure to oxygen-poor (10 -13 –10 -14 wt%) liquid lead-bismuth eutectic (LBE) at 500 °C for 500 h, LBE penetrates more than one order of magnitude deeper in an FCC Al 0.4 CoCrFeNi high-entropy alloy (HEA) decorated with a network of BCC (Ni, Al)-rich intergranular (IG) precipitates than in a single-phase, FCC Al 0.3 CoCrFeNi HEA without the IG precipitate network. This deterioration of corrosion resistance is attributed to the energetic nature of the BCC/FCC interphase boundaries (IBs) and resultant IB wetting. The LBE ingress film selectively leaches nickel located at those low-indexed crystalline planes, resulting in phase transformation from FCC to BCC structure.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Development of a Robust Reference Electrode in Aggressive Chemical and Radiation Environments in the Hanford Waste Tanks

The Hanford site stores more than 200 million liters of radioactive and chemically hazardous wastes from the production of weapons materials. The wastes are stored in 177 underground carbon-steel storage tanks, separated between 149 single shell tanks (SSTs) and 28 double shell tanks (DSTs). The DSTs provide critical retrieval and interim storage before the waste is vitrified in the Waste Treatment and Isolation Plant (WTP). The tanks will need to remain in-service far beyond the initial 40-year design life, and effective corrosion control practices must remain in force to extend the tanks’ lifespans. This effort includes direct measurements of corrosion rate (e.g., ultrasonic measurements and corrosion coupons) and electrochemical processes (e.g., linear polarization measurements and open circuit potential measurements). The Hanford site began monitoring the corrosion potential in select DSTs in 2008. Of the 45 reference electrodes that have been installed, 29 have failed and 6 others provided unreliable results. DOE-EM is supporting a 3-year program to develop a chemical and radiation resistant reference electrode for application in the Hanford tanks. The first year of the program focused on understanding the failure mechanism for the reference electrodes and identification of candidate construction materials that would mitigate degradation of the electrodes in the waste environment. During the second year of the program, the objectives were to: 1) test candidate materials under simulated waste conditions, 2) design components that will extend the service life of the electrode, 3) fabricate materials for prototype reference electrodes, and 4) assemble prototype reference electrodes for accelerated testing. The reference electrode is constructed of four principal parts: 1) junction, 2) casing, 3) inner chamber backfill materials, and 4) the sensing wire. Principally, improvements of the junction, casing, and inner chamber backfill materials are being pursued. The junction material at the interface between the waste and the inner chamber of the reference electrode was identified as a critical component in the failure of the reference electrodes. Nine candidate replacement junction materials were tested under simulated waste conditions to evaluate permeation rate. These materials included a variety of polymeric and ceramic materials, some of which were 3-D printed. Thus far, porous polyvinylidene fluoride materials have performed satisfactorily and are being considered for prototype development. The commercial electrode casing materials in general have performed well. Additionally, 3-D printing of chemically and mechanically stable materials is being investigated as a means for further improvement in fabrication consistency. SRNL has also investigated altering the reference electrode design to extend the service life. The new design of the interior of the reference electrode casing creates a longer, more tortuous path between the junction material and the electrode sensing wire. A finite element model was used to optimize the design without adversely impacting the circuit resistance of the electrode during the measurements, thus preserving the measurement accuracy while enhancing the service life. The inner chamber back fill materials are also critical to the performance of the reference electrode. Materials that are resistant to intruding tank waste and provide a conductive path to the sensing wire were investigated. Gel and powder materials that are interspersed with a conductive chloride bearing material were tested for their influence on diffusion and electrode resistance. All the investigated materials and components will be assembled, with collaboration from commercial vendors, to fabricate the initial prototypes. Accelerated testing of the prototypes will be initiated in Year 2 of the program and will be completed in Year 3. A recommendation on the materials of construction and the design of the new robust reference electrode will be presented to the Hanford tank farm facility.

Sykes, Kiana [Savannah River National Laboratory (↗

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↗