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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Nanoindentation Investigation of Chloride-Induced Stress Corrosion Crack Propagation in an Austenitic Stainless Steel Weld

Transgranular chloride-induced stress corrosion cracking (TGCISCC) is a mounting concern for the safety and longevity of arc welds on austenitic stainless steel (AuSS) nuclear waste storage canisters. Recent studies have shown the key role of crystallography in the susceptibility and propagation of TGCISCC in SS weldments. Given that crystallography underlies mechanical heterogeneities, the mechanical-crystallographic relationship during TGCISCC growth must be understood. In this study, welded SS 304L coupons are loaded in four-point bend fixtures and then boiled in magnesium chloride to initiate TGCISCC. Nanoindentation mapping is paired with scanning electron microscopy (SEM) electron backscatter diffraction (EBSD) to understand the correlation between grain orientation, grain boundaries, and hardening from TGCISCC propagation. The nanoindentation hardness of individual grains is found to not be a controlling factor for TGCISCC propagation. However, intragranular hardness is generally highest immediately around the crack due to localized strain hardening at the crack tip. This work shows that nanoindentation techniques can be useful in understanding CISCC behaviors when paired with electron microscopy.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Latent Catalysis as a Platform for Accessing Diverse Material Properties in Vat Photopolymerization 3D Printing

Vat photopolymerization (VP) 3D printing is an attractive strategy to manufacture customized polymer parts. The properties of printed materials are limited by the need to employ a low viscosity liquid resin and achieve rapid polymerization kinetics. To circumvent this limitation, dual‐cure methods have been developed using reagents embedded in the liquid resin formulation; however, the reagent‐based approach requires the discovery and optimization of new chemistry for each desired material. Here, in this work, we demonstrate a catalytic, dual‐cure platform that enables access to both Nylon‐6 and polyester interpenetrating networks through VP 3D printing under a universal approach. Structure–reactivity relationships of the latent NHC catalysts led to the identification of a magnesium chloride–NHC adduct as a latent catalyst that is orthogonal to radical polymerization and can be unmasked at elevated temperatures post‐printing to initiate ring‐opening polymerization of lactones and lactams. This strategy results in access to semicrystalline materials, which are a challenging morphology to access via VP 3D printing, that have attractive mechanical properties and can be printed at high resolution. This work represents the first photochemical‐based 3D printing of Nylon‐based materials and demonstrates the value of catalytic approaches to access new material properties in VP 3D printing.

Colliver, Cali N. [University of North Carolina, C↗
DOE OSTI2026

Mechanistic transition of stainless steel 304L corrosion in MgCl 2 phase change material under thermal cycling

Magnesium chloride (MgCl 2 )-based molten salt phase change materials (PCMs) are promising candidates for thermal energy storage (TES) owing to their advantageous thermophysical properties, however, their high corrosivity in the molten state limits material compatibility. In this study, the corrosion behavior of 304?L stainless steel (SS304L) exposed to MgCl2 PCM was investigated as a function of thermal cycling (up to 9000 cycles) relevant to PCM-based TES systems. Microstructural changes and elemental redistribution at the alloy-salt interface under thermal cycling conditions were characterized using synchrotron-based X-ray fluorescence (XRF) and scanning electron microscopy coupled with energy dispersive X-ray spectroscopy (SEM-EDS). Results show that corrosion is governed by selective Cr-dissolution and elemental diffusion near the interface and grain boundaries. A clear transition in the dominant corrosion mechanism is observed with increasing thermal cycles. Surface corrosion is the dominant mechanism up to 1000 cycles, whereas intergranular corrosion becomes the primary degradation mode beyond 2000 cycles. These mechanistic changes are interpreted in terms of evolving interfacial chemistry, microstructure and the diffusion-driven redistribution of alloying elements.

36 MATERIALS SCIENCE↗
DOE OSTI2025

The role of moisture in MgCl 2 salt: A multiscale approach to TES performance

This study presents a comprehensive multiscale analysis to evaluate the influence of moisture on the thermal performance of thermal energy storage systems using magnesium chloride (MgCl 2 ) as the phase-changing material. The system uses graphite foam with 90% relative density to enhance thermal conductivity. The analysis includes thermal conductivity calculations and specific heat capacity for different hydrate phases of MgCl 2 : Anhydrous, Mono, Di, Tetra, and Hexa. These properties were evaluated for the first time using the phonon density of states from Density Functional Theory simulations. Results showed that thermal conductivity decreased, while specific heat capacity increased by a factor of two as the phase changed from anhydrous to hexahydrate. Meso-scale models were created to account for the anisotropy of graphite foam and property variations of the MgCl 2 hydrate phases. Asymptotic Expansion homogenization simulations determined the anisotropic thermal conductivity for all phases. This unique methodology improved simulation accuracy, which matched experimental data for anhydrous MgCl 2 . A parametric study examined various operating conditions and their effect on TES performance. It revealed that higher charging temperatures did not enhance exergy efficiency, but increased discharge mass flow rates improved it due to better heat transfer. Thermal performance evaluated by the exergy efficiency remained consistent across hydrate systems under the tested conditions. Furthermore, the study suggests that this uniformity is linked to missing key data, particularly latent heat and melting point for different hydrates. Overall, it highlights the importance of multiscale effects and accurate material properties in designing and optimizing TES systems.

Molten salt degradation↗
DOE OSTI2026

An Analysis of Energy Needs and Seawater Extraction Approaches for the Integration of Primary Magnesium Production with Nuclear Power

The cost of primary magnesium production is highly dominated by the energy required to produce the metal. This, along with the current geographical concentration of its production, makes the magnesium price vulnerable as energy-production paradigms begin to rapidly change. In this work, four nuclear-integration pathways for the efficient supply of heat and electricity to magnesium production from a nuclear power plant are considered. A production route using electrified metallothermic reduction is compared to a nuclear-heat-integrated electrolytic pathway. It is shown that the latter can achieve significantly lower primary energy consumption, 261 MJ/kg Mg compared with 416 MJ/kg Mg. The electrolytic pathway can also reduce emissions down to around 2.1 kgCO2/kg Mg, compared to around 34 kgCO2/kg Mg in the Pidgeon process. Beyond energy and emissions, the four pathways considered are also compared to their ability to reduce locational dependence of the production plant and reduce process complexity. This work also highlights future advances in magnesium production with a potential scheme for the efficient extraction of magnesium from seawater with coproduction of desalinated water and the potential of demand-side response from magnesium electrolysis. This is the first work to consider the full integration of primary magnesium production using nuclear cogeneration, and it is hoped the study paves the way for the analysis of economic nuclear integration within metal extraction and manufacturing.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Real-Space Local Dynamics of Molten Inorganic Salts Using Van Hove Correlation Function

Molten inorganic salts are attracting resurgent attention because of their unique physicochemical properties, making them promising media for next-generation concentrating solar power systems and molten salt reactors. The dynamics of these highly disordered ionic media is largely studied by theoretical simulations, while the robust experimental techniques capable of observing local dynamics are not well-developed. To provide fundamental insights into the atomic-scale transport properties of molten salts, we report the real-space dynamics of molten magnesium chloride at high temperatures employing the Van Hove correlation function obtained by inelastic neutron scattering. Overall, our results directly depict the distance-dependent dynamics of a molten salt on the picosecond time scale. This study demonstrates the capability of the developed approach to describe the locally correlated- and self-dynamics in molten salts, significantly improving our understanding of the interplay between microscopic structural parameters and their dynamics that ultimately control physical properties of condensed matter in extreme environments.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Development of Data-Driven Models for Performance Prediction and Chemical Dosing of a Full-Scale Controlled Phosphorus Precipitation Reactor

This study evaluated the use of data-driven models to improve control of a struvite precipitation reactor that removes phosphorus from wastewater while producing a fertilizer product. The researchers developed predictive models for influent orthophosphate concentration, effluent orthophosphate concentration, and phosphorus removal using operational data from a full-scale MagPrex™ reactor at a water resource recovery facility in Denver, Colorado. Model predictions were used to recommend magnesium chloride dosing adjustments needed to achieve a target effluent phosphorus concentration. Several machine learning approaches were tested, with ridge regression providing the best predictions for influent orthophosphate concentration and phosphorus removal, and XGBoost providing the best predictions for effluent orthophosphate concentration. Simulation results indicated that the decision-support approach could correctly identify dosing adjustments in most cases and reduce chemical use. Full-scale implementation achieved lower accuracy due to changing operating conditions and limited historical data in some operating ranges. Here, the results demonstrate the potential of data-driven tools to support phosphorus recovery process control while also identifying practical limitations that affect deployment in full-scale systems.

42 ENGINEERING↗
DOE OSTI2021

Measuring the residual stress and stress-corrosion cracking susceptibility of additively manufactured 316L by ASTM G36-94

Residual stress is a contributor to stress-corrosion cracking (SCC) and a common byproduct of additive manufacturing (AM). In this work, the relationship between residual stress and SCC susceptibility in laser powder bed fusion AM 316L stainless steel was studied through immersion in saturated boiling magnesium chloride per ASTM G36-94. The residual stress was varied by changing the sample height for the as-built condition and additionally by heat treatments at 600, 800, and 1200 °C to control, and in some cases reduce, residual stress. In general, all samples in the as-built condition showed susceptibility to SCC with the thinner, lower residual stress samples showing shallower cracks and crack propagation occurring perpendicular to melt tracks due to local residual stress fields. The heat-treated samples showed a reduction in residual stress for the 800 and 1200 °C samples. Both were free of cracks after >300 hours of immersion in MgCl 2 , while the 600 °C sample showed similar cracking to their as-built counterpart. Geometrically necessary dislocation (GND) density analysis indicates that the dislocation density may play a major role in the SCC susceptibility.

36 MATERIALS SCIENCE↗
DOE OSTI2020

SPRUCE Precipitation Chemistry and Bulk Atmospheric Deposition Beginning in 2013

This data set reports the chemistry of precipitation water that was collected at the SPRUCE site located in the S1 bog and calculated values of bulk atmospheric deposition of solutes in precipitation. Sample collection and analyses started during December of 2013 and will continue for the duration of the experiment. Precipitation samples were collected year round on an event-basis from up to three individual collectors. Samples were either composited or individually analyzed, depending on the total volume of water available relative to the amount needed to complete all laboratory analyses. Funnel/bottle collectors were used to collect rainfall and buckets were used to collect snowfall and mixed precipitation. Samples were analyzed for pH, specific conductivity, nutrient concentrations (ammonium, nitrate, soluble reactive phosphorus, total nitrogen), cation concentrations (calcium, magnesium), anion concentrations (chloride, sulfate), total organic carbon concentrations, and natural-abundance stable isotopes of water (δ18O-H2O and δD-H2O). Bulk deposition was calculated by multiplying rainfall amount by solute concentration for ammonium, nitrate, soluble reactive phosphorus (SRP), total nitrogen, calcium, magnesium, chloride, sulfate, and total organic carbon. All measurements were made at the 8.1-ha S1 bog forest site in northern Minnesota, 40 km north of Grand Rapids, in the USDA Forest Service Marcell Experimental Forest (MEF).

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Density Measurements of Various Molten Sodium, Magnesium, Potassium, and Uranium Chloride Salt Compositions Using Neutron Imaging

With an increased interest in the use of molten salts for energy generation, obtaining thermophysical properties of salt mixtures becomes critical for the understanding of salt performance and behavior. Density is one of the significant thermophysical properties of salt systems. This work presents the density measurement of molten chloride salt mixtures using neutron imaging. This work was performed at the Oak Ridge National Laboratory High-Flux Isotope Reactor. Here, resulting densities as a function of temperature for different molten chloride salts from this work were compared with calculated values using Redlich–Kister modeling. Agreement between the calculated and measured values was within 1–10%, with the exception of the ternary UCl 3 –NaCl–KCl salt that showed a 32% discrepancy between several literature reports; however, the results did align well with another neutron radiography article. Analysis of the radiographs suggests that microbubbles in the ternary mixture might have biased the density measurements.

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

Mechanochemical Synthesis of High-Purity Anhydrous Binary Alkali and Alkaline Earth Chloride Mixtures

A direct synthesis route for high-purity, anhydrous binary salt mixtures has been developed. This atom efficient, solvent-free process is easily scalable, with the potential to produce salt mixtures that meet the purity standards required for industrial heat transfer and nuclear applications. The essence of the methodology lies in mechanochemical synthesis of carnallite precursors that can mitigate the hydrolysis of MgCl 2 ·6H 2 O under direct heating. Each dehydrated salt carnallite was then analyzed for purity and oxide content through subsequent powder X-ray diffraction, and strong acid titration. In conclusion, this process presents a more effective alternative route compared to previous methods for obtaining low-oxide, high-purity chloride salt mixtures.

Alkali↗
DOE OSTI2020

Quantitative assessment of environmental phenomena on maximum pit size predictions in marine environments

Maximum pit sizes were predicted for dilute and concentrated NaCl and MgCl 2 solutions as well as sea-salt brine solutions corresponding to 40% relative humidity (RH) (MgCl 2 -rich) and 76% RH (NaCl-rich) at 25 °C. A quantitative method was developed to capture the effects of various cathode evolution phenomena including precipitation and dehydration reactions. Additionally, the sensitivity of the model to input parameters was explored. Despite one's intuition, the highest chloride concentration (roughly 10.3 M Cl – ) did not produce the largest predicted pit size as the ohmic drop was more severe in concentrated MgCl 2 solutions. Therefore, the largest predicted pits were calculated for saturated NaCl (roughly 5 M Cl – ). Next, it was determined that pit size predictions are most sensitive to model input parameters for concentrated brines. However, when the effects of cathodic reactions on brine chemistry are considered, the sensitivity to input parameters is decreased. Although there was not one main input parameter that influenced pit size predictions, two main categories were identified. Under similar chloride concentrations (similar RH), the water layer thickness (WL), and pit stability product, (i · x) sf , are the most influential factors. When varying chloride concentrations (RH), changes in WL, the brine specific cathodic kinetics on the external surface (captured in the equivalent current density (i eq )), and conductivity (k o ) are the most influential parameters. Finally, it was noted that dehydration reactions coupled with precipitation in the cathode will have the largest effect on predicted pit size, and cause the most significant inhibition of corrosion damage.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Effects of Particle Size and Concentration of Magnesium Oxide on the Lubricating Performance of a Chloride Molten Salt for Concentrating Solar Power

One engineering challenge for the next-generation concentrating solar power (CSP) is to identify appropriate heat transfer and thermal energy storage media. A chloride salt mixture (20 wt % NaCl + 40 wt % MgCl 2 + 40 wt % KCl) in a molten phase is proposed as a potential fluid for carrying the heat as well as lubricating the CSP pump bearings. Due to the hygroscopic nature of MgCl 2 , the presence of magnesium oxide (MgO) particles is inevitable. In order to understand the impact of MgO particles, this study investigated the tribological behavior of the molten chloride salt mixture containing MgO of various particle sizes and concentrations. Tests were conducted at 750 °C in a dry Ar environment using a zirconia ball sliding against a Haynes 244 alloy disc lubricated by the molten salt. There was a clear trend of the increased friction coefficient and wear loss for a larger particle size and/or a higher concentration of MgO. Distinct wear mechanisms were identified for the ceramic ball and alloy disc. Results provide fundamental insights for this new research avenue of molten salt lubrication for CSP.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Denudation, solute export, landscape evolution modeling, and geographic information system data for the East River watershed, Colorado, USA (2020-2024)

This data package contains geographic information system (GIS) layers and tabular datasets associated with the study of lithologic controls on denudation, solute export, carbon-scaling relationships, and transient landscape evolution in the East River watershed near Crested Butte, Colorado, USA. The package includes GIS layers used to produce the Figure 2 map, including drainage, hillshade, lithology, sample locations, and basin polygons, together with comma-separated value (CSV) tables and matching CSV data dictionaries. One group of tables reports sample-level and catchment-level information for river-sediment samples analyzed for in situ-produced cosmogenic beryllium-10 (10Be), including sample names, outlet elevations, geographic coordinates, upstream drainage area, rock-type classes, production-rate scaling scheme, analyzed nuclide, catchment-averaged denudation rates, and associated lower and upper analytical uncertainties. Sample and catchment attributes provide the basis for comparing denudation rates across intrusive, shale, sedimentary, and mixed-lithology settings. A second group of tables reports supporting information for landscape-evolution modeling and the mapped geologic framework of the study area. Included files list parameter values and definitions for the two-phase landscape-evolution simulations, summarize full-domain model erosion fluxes and topographic metrics for different simulation configurations, provide a fixed-area carbon-model scaling table, and summarize mapped geologic units within the East River study domain, including geologic code, formation name, lithologic description, mapped area, and lithologic class grouping. Model outputs and geologic summaries support interpretation of transient landscape behavior and its relation to the mapped distribution of shale, intrusive, sedimentary, and surficial units. A third group of tables reports hydrologic and hydrochemical information used to quantify dissolved export from the watershed. Included files provide site-level values for drainage area, mean annual solute export, standard error of annual export, area-normalized solute yield, and equivalent weathering rate for five East River monitoring sites, along with metadata describing the number, sampling cadence, and date range of discharge records and partial and full total dissolved solids observations used in the solute-yield analyses. The package also contains a supplementary daily ion-load time series with daily mean discharge, discharge observation counts, dissolved concentrations, and daily loads for calcium, magnesium, sodium, potassium, chloride, sulfate, nitrate, fluoride, dissolved silica, charge-balance bicarbonate, and total dissolved solids. The package contains GIS files, comma-separated value files (.csv), CSV data dictionaries, a file-level metadata table, a package-tree text file, and a readme text file.

10Be↗
DOE OSTI2021

Hydrogenous Content in Residues from Aqueous Chloride Pu and Am Recovery Operations

Byproduct residues generated from Aqueous Chloride Pu and Am recovery operations at Los Alamos National Laboratory have been investigated and determined to contain high weight % chloride salts and minimal hydrogen content. Hydrogen content is the result of limited surface area adsorption of ambient moisture. The assumption used in technical analysis NCS-TECH-19-029 to model potentially hydrogenous items as mixtures of polyethylene is shown to be overly conservative. Our results and literature precedent indicate that water adsorption of 1-3 % by weight is expected for hydroxide cakes and Pu oxides, and a conservative bounding assumption for these materials is 5% water by weight. LOH results for a dissolution heel stored long term showed 6.25% weight loss, which was conservatively assumed to be water. A conservative bounding assumption for dissolution heels is 8 wt.% water content. This equates to 0.55 % hydrogen by weight for hydroxide cakes, and 0.88% hydrogen by weight for dissolution heels. The bulk composition of dissolution heels reflects the composition of the original byproduct feed material, chloride salts of potassium, sodium, magnesium and calcium. The bulk composition of calcined hydroxide precipitation residues is composed of potassium chloride as a result of potassium hydroxide neutralization of hydrochloric acid solutions. Metal hydroxides generated during the hydroxide precipitation process are decomposed under the conditions of calcination to metal oxide forms.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Molten salt compositions with enhanced heat transfer and reduced corrosion properties

A heat transfer (exchange) composition comprising a halide salt matrix having dispersed therein nanoparticles comprising elemental carbon in the absence of water and surfactants, wherein said halide is fluoride or chloride, wherein the halide salt may be an alkali halide salt (e.g., lithium fluoride, sodium fluoride, potassium fluoride, rubidium fluoride, sodium chloride, potassium chloride, rubidium chloride, and eutectic mixtures thereof) or an alkaline earth halide salt (e.g., fluoride or chloride salt of beryllium, magnesium, calcium, strontium, or barium), and wherein the nanoparticles comprising elemental carbon may be solid or hollow, and wherein the composition may further include nanoparticles comprising a fissile material (e.g., U, Th, or Pu) dispersed within the composition. Molten salt reactors (MSRs) containing these heat transfer compositions in coolant loops in thermal exchange with a reactor core, as well operation of such MSRs, are also described.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗