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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Strengthening mechanisms for microstructures containing unimodal and bimodal γ' precipitates in ATI 718Plus

Here, the influence of γ' precipitate size distribution on the deformation mechanisms under tensile loading in ATI 718Plus was studied. A set of aging treatments within the temperature range of 720 °C–900 °C was performed on solution-treated samples to obtain various γ' precipitate size distributions. Unimodal and bimodal γ' precipitate size distributions were achieved through single-step and two-step aging sequences, respectively, and such microstructures were tensile tested to failure to assess their yield strength, ultimate tensile strength, and elongation-to-failure. Some of the tensile samples were interrupted after achieving 3–4 % plastic strain, and the deformed microstructures were examined using transmission electron microscopy to investigate the γ' precipitate-dislocation interactions. For the unimodal γ' precipitate size distribution samples with the smaller γ' precipitates (radius ~ 7 nm), dislocations sheared through the precipitates. Both dislocation loops and paired dislocations were observed for the microstructures containing larger γ' precipitates (radius ~ 24 nm). The microstructure containing a bimodal γ' precipitate size distribution, which included average γ' precipitate radii of ~6 nm and ~28 nm, exhibited shearing as the dominant deformation mechanism, and this microstructure exhibited the highest strength values. The experimental observations were rationalized based on the theoretically-calculated critical resolved shear stress values for shearing and looping and a modified model for predicting the yield strength for bimodal microstructures was introduced.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Effect of Annealing on Direct Recycled NMC Cathodes

A substantial number of electric vehicle batteries are poised to reach end-of-life conditions in the next decade. Direct recycling has advantages over typical recycling processes because it preserves the chemical structure of the material. One key step of direct recycling materials like nickel manganese cobalt oxide (NMC) cathodes is relithiation, which includes replacing the depleted lithium inventory in the cathode and annealing the material to fix crystallographic degradation. This work uses multiple characterization techniques (synchrotron X-ray diffraction, Ni X-ray absorption near edge structure, scanning transmission electron microscopy) to understand the lithiation mechanism of degraded and chemically relithiated NMC 622. Despite the necessary reconstruction after relithiation being limited to the surface of the degraded NMC 622, a high annealing temperature of 720 °C is still necessary to restore the NMC 622 structure back to pristine condition after relithiation. This work also finds that treating degraded NMC 622 with an annealing step is sufficient to restore key electrochemical and structural properties, other essential features of pristine NMC 622 material such as particle porosity and morphology are largely unaffected. Understanding the effect of this annealing step has important implications on defining the degree of success of any given direct recycling strategy.

36 MATERIALS SCIENCE↗
DOE OSTI2024

CO 2 fixation into carbon nanofibres using electrochemical–thermochemical tandem catalysis

Carbon dioxide (CO 2 ) fixation into value-added solid carbon such as carbon nanofibres (CNF) for longer-term storage represents a promising avenue for achieving net-negative carbon emissions. However, directly converting CO 2 to CNF via thermocatalytic approaches faces thermodynamic constraints, while electrocatalytic methods typically lead to amorphous carbon with limited yields or require energy-intensive conditions (>720 °C). Here, we present an electrocatalytic-thermocatalytic tandem strategy for CNF production, which circumvents the aforementioned thermodynamic limitations by integrating the co-electrolysis of CO 2 and water into syngas (CO and H 2 ) with a subsequent thermochemical process at relatively mild conditions (370-450 °C, 1 atm), yielding CNF at a high production rate (average 2.5 g carbon g metals -1 h -1 ). Further, the optimal coordinated actions of FeCo alloy and extra metallic Co were ascertained to enhance the dissociative activation of syngas and favour the carbon-carbon bond formation to produce CNF. This tandem strategy opens a door to leverage renewable energy for decarbonizing CO 2 into valuable solid carbon products while producing renewable H 2 .

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

A Scalable Compact Additively Manufactured Molten Salt to Supercritical Carbon Dioxide Heat Exchanger for Solar Thermal Application

Design of an additively manufactured molten salt (MS) to supercritical carbon dioxide (sCO 2 ) primary heat exchanger (PHE) for solar thermal power generation is presented. The PHE is designed to handle temperatures up to 720 °C on the MS side and an internal pressure of 200 bar on the sCO 2 side. In the core, MS flows through a three-dimensional periodic lattice network, while sCO 2 flows within pin arrays. The design includes integrated sCO 2 headers located within the MS flow, allowing for a counterflow design of the PHE. The sCO 2 headers are configured to enable uniform flow distribution into each sCO 2 plate while withstanding an internal pressure of 200 bar and minimizing obstruction to the flow of MS around it. The structural integrity of the design is verified on additively manufactured (AM) 316 stainless steel sub-scale specimens. An experimentally validated, correlation-based sectional PHE core thermofluidic model is developed to study the impact of flow and geometrical parameters on the PHE performance, with varied parameters including the mass flowrate, surface roughness, and PHE dimensions. A process-based cost model is used to determine the impact of parameter variation on build cost. The model results show that a heat exchanger with a power density of 18.6 MW/m 3 (including sCO 2 header volume) and effectiveness of 0.88 can be achieved at a heat capacity rate ratio of 0.8. As a result, the impact of design and AM machine parameters on the cost of the PHE are assessed.

14 SOLAR ENERGY↗
DOE OSTI2020

Molten Chloride Thermophysical Properties, Chemical Optimization, and Purification

Next-generation concentrating solar power (CSP) technology requires high-temperature heat-transfer fluids and thermal energy storage that can operate in the temperature range of 500°–720°C. This high temperature demands a new chemistry for the heat-transfer fluids that must have high-temperature thermal and chemical stabilities, high energy density, and low corrosion rate on metallic materials used in the heat exchangers, piping, and thermal energy storage tanks. A ternary MgCl 2 -KCl-NaCl chloride-salt system has been proposed to achieve such goals, given its high-temperature thermal stability. The chloride-salt-based systems have been used by the metallurgy industry as the electrolyte to electrolytically extract metallic magnesium. They have also attracted attentions from the nuclear industry for developing the molten salt fast reactors that can operate at close to atmospheric pressure and at higher temperature than traditional light-water reactors. However, the corrosion properties of the ternary salt are not well known. The corrosion mechanism is believed to be correlated to the presence of MgOHCl impurity at the operation temperature. MgOHCl is fundamentally caused by the hygroscopic nature of the MgCl 2 component. Therefore, the first key objective of this project is to understand the nature of the corrosiveness of the ternary chloride-salt system and its prevention by designing new lab-scale purification processes. Because of its importance, a working group called the Chloride Salt Collective across multiple U.S. Department of Energy national laboratories is established to gain experimental agreement on the corrosion behaviors. In addition, water generation during salt dehydration could lead to highly corrosive HCl/water mixture via a hydrolysis process between water and anhydrous MgCl 2 or MgCl 2 hydrates. MgOHCl will eventually be converted to MgO particulates regardless of the chemical path chosen (i.e., by thermal decomposition, chemical purification with an active metal, or electrochemical purification utilizing the reduction power of electron flows). Large MgO particles with high hardness can wear out bearing and bushing and even clog the delicate channels in the primary heat exchanger. Because of this, a second objective is to understand the chemistry behind salt purification and transfer the scientific understanding to a set of engineering know-how for large-scale salt melter design. Because there is limited information on the thermophysical properties and the sensitivity of these properties around the targeted salt composition, a third objective is to measure thermophysical properties relevant to system and component design and support Topic 1 Liquid Pathway development. For example, composition shift due to salt reaction with water can be a potential issue because it can lead to changes of thermophysical properties, such as (1) melting point (or freeze point), which can jeopardize safe operation of the supercritical CO 2 power cycle proposed for next-generation CSP, and (2) heat capacity and density, which can decrease the overall power-generation capability of the plants. The value of the thermal conductivity of the selected salt composition is also a critical criterion for the solar receiver design.

14 SOLAR ENERGY↗
DOE OSTI2024

FY24 Integrated Results for High-Temperature Mechanical Testing of LPBF 316H Stainless Steel

This report provides the mechanical test data of laser powder bed fusion (LPBF) 316H stainless steel (SS) collected during Fiscal Year 2024 (FY 24) under the US Department of Energy, Office of Nuclear Energy’s Advanced Materials and Manufacturing Technologies program, along with the current state of microstructural-based understandings of the behaviors. Materials with variabilities in manufacturing site, machine, laser parameters, powder chemistry, porosity, specimen geometry and heat treatment were tested in high-temperature tension, creep, fatigue and creep-fatigue. Electron microscopy and optical microscopy were performed on selected materials before and after the tests to provide microstructural-based understandings to the mechanical behavior. It was discovered that the as-built (AB) and stress-relieved (SR) materials exhibit similar behaviors in tension and creep, as do the solution-annealed (SA) and hot-isostatic pressed (HIP) materials. The AB and SR materials are softer but more ductile than the SA and HIP materials in tension. In creep, the LPBF materials have comparable rupture times but lower rupture strains compared to the wrought materials. The AB and SR materials have low creep rupture strains (<10%) when tested at 720°C and 800°C, while the SA and HIP materials are much more ductile. The LPBF materials exhibit large scatter in fatigue and creep-fatigue lives. The cyclic lives of creep-fatigue tests are lower than those of fatigue tests. In fatigue and creep-fatigue, SR materials outperform SA materials. A common observation from the cyclic tests is that, given the same post-build heat treatment, a lower initial peak stress generally results in a longer cyclic life regardless of hold time. It was also discovered that the batch variation can be more impactful than heat treatment, as demonstrated by the overall better performance of one batch of material than another, regardless of the heat treatment. The results provided insights into how different factors impact the behaviors of LPBF 316H SS. An outlook to FY 25 work scope is provided.

36 MATERIALS SCIENCE↗
DOE OSTI2023

High Temperature Ternary Chloride Molten Salt Pump

A ternary chloride (MgCl2-NaCl-KCl) molten salt pump has been developed to operate up to 720°C. The design is the result of a thermal, structural and material study of critical components. The vertical overhung pump incorporates first of a kind salt-wetted hydrodynamic bearings. Several bearing material pairings were tested which include: colmonoy grades, stellite grades, and a novel NiWC-based alloy (i.e. HybrimetTM NiWC3b) used as a High Velocity Oxygen Fuel (HVOF) coating. The coating withstands the corrosion effects of the molten salt, and is also used to protect a 316L stainless steel pump reservoir. The pump bowl assembly components are made of Inconel 625. A Nitrogen flushed carbon ring seal is used to keep salt vapors from interacting with external ambient air. Preliminary testing shows a promising pump design for use in the Concentrating Solar Power Gen 3 systems and sets the ground for further development of the HybrimetTM NiWC3b as a competitive alternative to available superalloys.

Handy-Cardenas, Lewis (ORCID:0009000744006972)↗
NASA NTRS1981

Lattice defects in semiconducting Hg/1-x/Cd/x/Te alloys. III - Defect structure of undoped Hg0.6Cd0.4Te

Hall effect measurements were carried out on undoped Hg0.6Cd0.4Te crystals quenched to room temperature subsequent to equilibration at temperatures varying from 450 to 720 C under various partial pressures of Hg. The variation of the hole concentration as a function of the partial pressure of Hg indicates that the native acceptor defects are doubly ionized. Native donor defects are found to be negligible in concentration and the p-type to n-type conversion is shown to be due to residual donors and not due to native donor defects. Thermodynamic constant for the incorporation of the doubly ionized native acceptor defect has been established.

Vydyanath, H. R.↗
NASA NTRS1984

Effect of water on hydrogen permeability

Doping of hydrogen with CO or CO2 was developed to reduce hydrogen permeation in Stirling engines by forming low permeability oxide coatings in the heater tubes. An end product of this process is water - which can condense in the cold parts of the engine system. If the water vapor is reduced to a low enough level, the hydrogen can reduce the oxide coating resulting in increased permeability. The equilibrium level of water (oxygen bearing gas) required to avoid reduction of the oxide coating was investigated. Results at 720 C and 13.8 MPa have shown that: (1) pure hydrogen will reduce the coating; (2) 500 ppm CO (500 ppm water equivalent) does not prevent the reduction; and (3) 500 ppm CO2 (1000 ppm water) appears to be close to the equilibrium level. Further tests are planned to define the equilibrium level more precisely and to extend the data to 820 C and 3.4, 6.9, and 13.8 MPa.

Hulligan, D. D.↗
DOE OSTI2024

Method for electrochemical transformation of amorphous material to crystalline material

A method for converting amorphous boron nitride to crystalline boron nitride, the method comprising immersing the amorphous boron nitride into anhydrous molten magnesium chloride maintained within a temperature range of 720° C.-820° C. while the amorphous boron nitride is cathodically polarized at a voltage within a range of −2.2V to −2.8V for a period of time of at least 2 minutes to result in conversion of the amorphous boron nitride to the crystalline form. Also described herein is a method for converting an amorphous carbon material to a crystalline carbon material, the method comprising immersing said amorphous carbon material into anhydrous molten magnesium chloride maintained within a temperature range of 780° C.-820° C. while the amorphous carbon material is cathodically polarized at a voltage within a range of −2.2V to −2.8V for a period of time of at least 2 minutes to result in conversion of the amorphous carbon material to the crystalline form.

Bagri, Prashant↗
NASA NTRS1992

Observation of fullerenes (C60-C70) associated with LDEF crater number 31

The presence of fullerenes in and around the LDEF crater number 31 is reported. This crater has a high C level associated with it, and is interpreted as having been produced by the impact of a C-rich micrometeoroid. Fullerenes are large 3-D C structures, among which the species C sub 60 (MW 720) and C sub 70 (MW 840) are preeminent. Fullerenes have several UV absorption bands, hence fullerenes should be detectable using UV laser ionization time-of-flight mass spectrometry. We use a LIMA-2A instrument with pulsed UV laser (266 nm) to search for high mass C species associated with LDEF crater number 31. The mass range was 0 to 1200 amu. Low ablating laser power levels were used (less than or = 5 x 10 exp 7 W/sq. cm); 200 mass spectra were acquired and summed. We observed high mass signals near m/z 720, exhibiting 24 amu separation, which is characteristic of fullerenes. Alkali ion signals were also observed. Little or no C clusters of intermediate mass were observed. We interpret the signals around m/z 720 as fullerenes, mainly C sub 60+ with lower levels of C sub 70+. We propose that the mechanism that produces these signals is resonant multiphoton ionization (REMPI). This selective mechanism explains why low mass C cluster ions are not observed along with the fullerenes, since they have much higher ionization potentials. This finding is unexpected, since up to now the search for fullerenes in extraterrestrial materials has not been successful. We conclude that the fullerenes became associated with crater number 31 in space. Two alternative (and exciting) scenarios are being considered at this time: either the fullerenes were carried by the C-rich projectile that formed crater number 31, or the fullerenes formed upon impact with the LDEF. We show the results of experiments at the ARC Vertical Gun Facility, which may establish some constraints on the origin of the fullerenes.

Radicatidibrozolo, Filippo↗
DOE OSTI2023

Influence of interrupted cooling on the development of bimodal γ' precipitate distributions in ATI 718Plus

The influence of aging treatments on the evolution of the γ' precipitates in ATI 718Plus was studied using scanning electron microscopy, energy dispersive spectroscopy, transmission electron microscopy, and atomic probe tomography. A set of aging treatments was performed on solution-treated samples to obtain various γ' size distributions. The aging temperatures ranged from 720 to 900°C with holding times of either two hours (for the 900°C aging temperature) or 10 h (for the 720°C and 750°C aging temperatures) followed by either air cooling, furnace cooling, or water quenching. The cooling method and aging temperature influenced the distribution of the solute elements. This work discussed the evolution of the γ' precipitation during single-step aging and two-step aging involving continuous cooling or interrupted cooling. Finally, a bimodal size distribution of the γ' precipitates was obtained through interrupted cooling two-step aging treatments, while single-step aging resulted in unimodal γ' precipitate distributions.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Probing thermodynamics of radiogenic helium and defects in $δ$-plutonium alloys and interactions with adsorbed environmental gases

Differential scanning calorimetry coupled with simultaneous evolved gas analysis (DSC-EGA) on aged δ-Pu samples shows that most radiogenic helium remains trapped within the Pu matrix at temperatures very close to, or slightly above, the melting temperature. Our results indicate that helium release from 50-year-old δ-Pu occurs as a burst just below the melting temperature (>0.994 T m ), with subsequent pressure oscillations as temperature increases. Subordinate quantities of H 2 were also released along with helium. Here, the helium emission tails off and ceases above ~720 – 750°C. In a δ-Pu alloy aged 6 years, the initial helium burst occurs slightly above melting (~1.015 – 1.042 T m ), with a discrete, larger helium spike occurring between 670 and 686°C. The proximity of helium release to the liquidus transition presented challenges in the deconvolution of overlapping process enthalpies, the liquidus endotherm, and the exotherm resulting from bubble collapse, annealing and gas expulsion. Helium’s strong affinity for vacancy binding in a 2He-vac configuration is predicted by Density Functional Theory (DFT) modeling. The measured stored energy associated with the He release events in a 50-year-old δ alloy is on the order of ~ 10–11 J/g, which is significantly higher than stored energies measured in the sub-solidus regimes (~2 J/g) that are related to the solid-state annealing of processing- and radiation-induced defects. This implies that aged δ Pu alloys have a remarkable resilience to accommodate the lattice strain produced by the internal pressure of the helium bubbles and provides further insight into the thermodynamic behavior of aged δ Pu.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Demonstrate and De-Risk an Internally Lined Tank Design for Molten-Salt Thermal Energy Storage Benefitting CSP and Nuclear-Energy Sectors

The LIMOSA project extends the Gen3 CSP "Liquid Pathway" project to evaluate 720 degrees C thermal energy storage based on molten chloride salts. While SETO selected the Particle Pathway for Gen3 demonstration, LIMOSA was created to resolve a major risk factor with molten chloride salts - the design of the salt storage tank. The project team designed and assembled a test system leveraging experience from Oak Ridge National Lab and the Liquid Pathway Phases 1 and 2. The key innovation in the project is development of a graphite-foil barrier to protect insulation from salt intrusion and wetting.

chloride salt↗
NASA NTRS2011

Characterization of 720 and 940 MHz Oscillators with Chip Antenna for Wireless Sensors from Room Temperature to 200 and 250 deg C

Oscillators that operate at 720 and 940 MHz and characterized over a temperature range of 25 C to 200 C and 250 C, respectively, are presented. The oscillators are designed on alumina substrates with typical integrated circuit fabrication techniques. Cree SiC MESFETs, thin film metal-insulator-metal capacitors and spiral inductors, and Johanson miniature chip antennas make-up the circuits. The output power and phase noise are presented as a function of temperature and frequency. Index Terms MESFETS, chip antennas, oscillators SiC alumina.

Scardelletti, Maximilian C.↗
NASA NTRS1983

Automotive Stirling engine development program - Overview and status report

The current status of the automotive-Stirling-engine development program being undertaken by DOE and NASA Lewis is reviewed. The program goals and the reference-engine design are explained, and the modifications introduced to improve performance and lower manufacturing costs are discussed and illustrated, including part-power optimization; increased operating temperature (from 720 to 820 C); 45.4-kg weight reduction; elimination of Co and reduction of Cr used; and improved seals, ceramic components, and high-temperature alloys. The test program, some difficulties encountered, and results after 2042 h are summarized.

Nightingale, N. P.↗
DOE OSTI2024

Safety and efficacy of C. muridarum vaccines adjuvanted with CpG-1826 and four concentrations of Montanide-ISA-720-VG

It is recommended that the adjuvant Montanide ISA 720 VG be used at a concentration of 70% v/v. At this concentration, Montanide causes at the site of immunization a local granuloma that can last for several weeks. To determine the safety and protective efficacy of a Chlamydia muridarum MOMP vaccine, formulated with CpG-1826 and four different concentrations of Montanide (70%, 50%, 30% and 10%), BALB/c (H-2 d ) female mice were immunized twice intramuscularly. Local reactogenicity was significant for vaccines formulated with 70% or 50% Montanide but not for those inoculated with 30% or 10% Montanide. Robust humoral and cell mediated memory immune responses were elicited by the 70%, 50% and 30% Montanide formulations. Mice were challenged intranasally with 10 4 C. muridarum inclusion forming units (IFU). Based on changes in body weight, lungs’s weight and number of IFU recovered, mice vaccinated with the 70%, 50% and 30% Montanide formulations were significantly protected, but not mice receiving 10% Montanide. To conclude, we recommend the 30% Montanide concentration to be tested in humans and animal models to determine its safety and efficacy, in comparison to the 70% Montanide concentration currently used. The 30% Montanide formulation could significantly facilitate licensing of this adjuvant for human use.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2020

Short-Term Stable Isotope Probing of Proteins Reveals Taxa Incorporating Inorganic Carbon in a Hot Spring Microbial Mat

The upper green layer of the chlorophototrophic microbial mats associated with the alkaline siliceous hot springs of Yellowstone National Park consists of oxygenic cyanobacteria ( Synechococcus spp.), anoxygenic Roseiflexus spp., and several other anoxygenic chlorophototrophs. Synechococcus spp. are believed to be the main fixers of inorganic carbon (C i ), but some evidence indicates that Roseiflexus spp. also contribute to inorganic carbon fixation during low-light, anoxic morning periods. Contributions of other phototrophic taxa have not been investigated. In order to follow the pathway of C i incorporation into different taxa, mat samples were incubated with [ 13 C]bicarbonate for 3 h during the early-morning, low-light anoxic period. Extracted proteins were treated with trypsin and analyzed by mass spectrometry, leading to peptide identifications and peptide isotopic profile signatures containing evidence of 13 C label incorporation. A total of 25,483 peptides, corresponding to 7,221 proteins, were identified from spectral features and associated with mat taxa by comparison to metagenomic assembly sequences. A total of 1,417 peptides, derived from 720 proteins, were detectably labeled with 13 C. Most 13 C-labeled peptides were derived from proteins of Synechococcus spp. and Roseiflexus spp. Chaperones and proteins of carbohydrate metabolism were most abundantly labeled. Proteins associated with photosynthesis, C i fixation, and N 2 fixation were also labeled in Synechococcus spp. Importantly, most proteins of the 3-hydroxypropionate bi-cycle for C i fixation in Roseiflexus spp. were labeled, establishing that members of this taxocene contribute to C i fixation. Other taxa showed much lower [ 13 C]bicarbonate incorporation. IMPORTANCE Yellowstone hot spring mats have been studied as natural models for understanding microbial community ecology and as modern analogs of stromatolites, the earliest community fossils on Earth. Stable-isotope probing of proteins (Pro-SIP) permitted short-term interrogation of the taxa that are involved in the important process of light-driven C i fixation in this highly active community and will be useful in linking other metabolic processes to mat taxa. Here, evidence is presented that Roseiflexus spp., which use the 3-hydroxypropionate bi-cycle, are active in C i fixation. Because this pathway imparts a lower degree of selection of isotopically heavy C i than does the Calvin-Benson-Bassham cycle, the results suggest a mechanism to explain why the natural abundance of 13 C in mat biomass is greater than expected if only the latter pathway were involved. Understanding how mat community members influence the 13 C/ 12 C ratios of mat biomass will help geochemists interpret the 13 C/ 12 C ratios of organic carbon in the fossil record.

59 BASIC BIOLOGICAL SCIENCES↗