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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

High temperature thermochemical energy storage materials

Disclosed are thermal energy storage systems and methods that utilize metal carbonate eutectics that can undergo high temperature reversible reactions to form mixtures of metal oxides. The metal oxides undergo an exothermic reaction with carbon dioxide to form the molten metal carbonate eutectics, and the molten metal carbonate eutectics undergo an endothermic decarbonization reaction to form the metal oxides and carbon dioxide. By carrying out the reversible reactions at a temperature above the melting point of the carbonate eutectic, the systems provide high thermal conductivity and reversible stability for thermal energy storage.

25 ENERGY STORAGE↗

Elucidating the Transition of 3D Morphological Evolution of Binary Alloys in Molten Salts with Metal Ion Additives

Molten salts serve as effective high-temperature heat transfer fluids and thermal storage media used in a wide range of energy generation and storage facilities, including concentrated solar power plants, molten salt reactors and high-temperature batteries. However, at the salt–metal interfaces, a complex interplay of charge-transfer reactions involving various metal ions, generated either as fission products or through corrosion of structural materials, takes place. Simultaneously, there is a mass transport of ions or atoms within the molten salt and the parent alloys. The precise physical and chemical mechanisms leading to the diverse morphological changes in these materials remain unclear. Here, to address this knowledge gap, this work employed a combination of synchrotron X-ray nanotomography and electron microscopy to study the morphological and chemical evolution of Ni-20Cr in molten KCl-MgCl 2 , while considering the influence of metal ions (Ni 2+ , Ce 3+ , and Eu 3+ ) and variations in salt composition. Our research suggests that the interplay between interfacial diffusivity and reactivity determines the morphological evolution. The summary of the associated mass transport and reaction processes presented in this work is a step forward toward achieving a fundamental comprehension of the interactions between molten salts and alloys. Overall, the findings offer valuable insights for predicting the diverse chemical and structural alterations experienced by alloys in molten salt environments, thus aiding in the development of protective strategies for future applications involving molten salts.

36 - MATERIALS SCIENCE↗

High-Voltage, Intermediate-Temperature, Fe- and Al-Mixed Metal Halide Molten Salt for Molten Sodium Battery Energy Storage

An inorganic Fe and Al halide-based, low-temperature molten salt catholyte is described, which, when paired with a molten sodium anode, has high operating potentials rivaling those of Li ion batteries. The newly developed catholyte consists of metal halides FeCl 3 /FeCl 2 –AlCl 3 –NaCl and is intended to cycle between Fe 3+ /Fe 2+ redox couples in the molten salt. The multicomponent molten salt was initially evaluated for phase behavior and basic electrochemical behavior before full battery testing. The assembled battery, utilizing a 20:35:45 (FeCl 3 :AlCl 3 :NaCl) composition, with a 50.83 Ah/kg theoretical gravimetric capacity and a specific energy of 176.95 Wh/kg, was cycled at variable depths of discharge (DoD) and current densities to determine its cycling efficiencies and limitations. In conclusion, preliminary cycling tests showed two operational potential regimes, with higher potential, 3.91 V (vs Na/Na + ), at low DoD and lower potential, 3.39 V (vs Na/Na + ), at high DoD with excellent energy efficiencies and cycling behavior under both regimes.

Aluminum↗

Material Interactions in Severe Accidents – Benchmarking the MELCOR V2.2 Eutectics Model for a BWR-3 Mark-I Station Blackout: Part II – Uncertainty Analysis

Single case comparisons between severe accident simulations can provide detailed insights into severe accident model behavior, however, they cannot offer insights into model uncertainty, sensitivity to uncertain parameters, or underlying model biases.Here in this analysis, the single case benchmark comparison of the MELCOR material interaction models for a station blackout (SBO) scenario of a boiling water reactor (BWR) using representative Fukushima Daiichi Unit 1 boundary conditions is expanded to include an uncertainty analysis. As part of this uncertainty analysis, 1200 simulations are performed for each material interaction model (2400 total), with random sampling of 14 uncertain MELCOR input parameters. Input parameters are selected for their impact on models representing core degradation processes. These include candling, fuel rod failure, debris quenching and dryout. The analysis performed here is not a traditional “best-estimate” uncertainty analysis that uses best-estimate parameters or identifies best-estimate figure of merit distributions. Instead, it is an exploratory uncertainty analysis that identifies and interrogates underlying model form biases of the two material interaction models (eutectics and interactive materials models). Uniform distributions are applied to all uncertain parameters to ensure coverage of the model parameter uncertainty space. Key findings from this study include underlying model form biases exhibited by material interaction models, and notable differences in accident progression outcomes between the material interaction models. This uncertainty study extends and confirms the conclusions from the first part of this study, which compared the impact of material interaction modeling on simulation of a short-term station blackout scenario with representative Fukushima Daiichi Unit I boundary conditions. In particular, this study confirms that the eutectics model generally exhibits accelerated degradation and failure of fuel components, the core plate, and the lower head. The eutectics model also has a tendency to exhibit a greater degree of core degradation, greater debris mass formation, and larger debris mass ejection. Finally, the eutectics model exhibits higher maximum temperatures for fuel, cladding, particulate debris, oxidic molten pool, and metallic molten pool components than the interactive materials model; interactive materials model simulations exhibit a soft “limitation” on maximum temperatures that is related to the temperature at which material relocation occurs.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

System and method of making an enhanced cast iron crankshaft

A method and system for manufacturing a cast iron crankshaft for a vehicle are provided. The system comprises a molding unit arranged to form a negative sand cast mold of the cast iron crankshaft. The mold comprising at least one molded cavity having a pattern with dimensions of the cast iron crankshaft. The system further comprises a feeding mechanism comprising a riser having a connector through which molten metallic material flows to the cast mold. The feeding mechanism feeds the molten metallic material at a riser connection angle in the at least one mold cavity. The riser connection angle corresponds to a connector modulus. The connector modulus is 20% greater than a cast modulus. The riser geometry corresponds to a riser modulus. The riser modulus is 20% greater than the connector modulus. The system further comprises a furnace, a cooling area, a separation unit, a controller and a power source.

Wang, Liang↗

Chlorination of uranium metal in molten NaCl-CaCl 2 via bubbling HCl

Molten chloride salt fast reactors (MCFRs) will require UCl 3 dissolved in molten salt mixtures as fuel for nuclear fission. For infusing the salt with UCl 3 , bubbling HCl into NaCl-CaCl 2 in contact with U metal was investigated. The reaction was run up to 9 h and yielded U concentration up to 0.652 wt.%. Open circuit potential between a W electrode and Ag/AgCl reference electrode yielded a potential consistent with uranium existing as U(III) in the salt. Furthermore, this demonstrates that HCl can be a very effective chlorinating agent to infuse MCFR fuel with UCl 3 starting from U metal.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Method for making metal-nanostructured carbon composites

A method for making covetic metal-nanostructured carbon composites or compositions is described herein. This method is advantageous, in that it provides substantially oxygen-free covetic materials and allows precise control of the composition of the covetic material to be produced. The method comprises introducing carbon into a molten metal in a heated reactor under low oxygen partial pressure, while passing an electric current through the molten metal. The reactor is heated at a temperature sufficient to form a network of nanostructured carbon within a matrix of the metal. After heating the covetic material is recovered from the reactor.

Balachandran, Uthamalingam↗

Electrochemical Modeling of Iodide Oxidation in Metal-Halide Molten Salts

The oxidation of iodide in NaI-AlBr 3 , NaI-AlCl 3 , and NaI-GaCl 3 molten salts was analyzed using simulation software to extract relevant kinetic parameters. The experimental oxidation potentials were ordered AlCl 3 < AlBr 3 < GaCl 3 , with higher oxidation potentials correlating with softer Lewis acidity of the metal halide. An iodide oxidation and metal halide speciation model was developed and simulated to fit the electrochemical response, enabling determination of electrochemical charge transfer parameters and chemical equilibrium constants. NaI-AlBr 3 displayed the fastest electron transfer rates yet showed the lowest current densities. All salts revealed smaller than expected current densities, explained by equilibrium between various species, where some are not electrochemically active at the studied potentials. These equilibrium reactions are due to the various metal halide species, controlling the reactant concentration of iodide and the resultant current. We hypothesize the electrochemically active iodide species, present as a metal halide monomer (MX 3 I − ), is decreased dramatically from the expected concentration, sequestered as a more stable metal halide dimer species (M 2 X 6 I − ) with a higher oxidation potential. Traditional Tafel analysis of the experimental data supports the validity of the simulations. These results increase understanding of iodide oxidation in low-temperature Lewis acidic molten salts and inform task-specific molten salt design.

Lee, Rose Y. (ORCID:0000000226587220)↗

High-Temperature Ferrofluids Based on Molten Salts

Molten metal chloride salts are promising candidates for advanced heat transfer fluids in generation IV nuclear reactors and beyond. However, research on the magnetic properties of suspended metallic nanoparticles at elevated temperatures is scarce, and there have been no attempts to develop a high-temperature, molten salt based ferrofluid. Such a ferrofluid would enable in situ manipulation of both the physical and thermal properties of the fluid via an external magnetic field. This study examines molten salt based ferrofluids comprised of metallic cobalt nanoparticles dispersed in molten metal chloride salts. High-temperature magnetometry and magneto-thermogalvometric measurements were conducted to evaluate the magnetic characteristics of the ferrofluid. Further analysis was conducted through a combination of microscopy, spectroscopy, solubility tests, and diffraction measurements. Furthermore, the metallic cobalt nanoparticles exhibited a notable degree of chemical stability and sustained magnetism from 25 to 800 °C when suspended in NaCl–MgCl 2 and KCl–ZnCl 2 mixtures.

Cobalt↗

Determine Oxidation State of Transition Metals in Molten Salt Corrosion using Electron Energy Loss Spectroscopy

This work utilizes electron energy loss spectroscopy (EELS) to identify oxidation state of alloying elements in Ni-based alloys after exposure to molten chloride salt systems. Pure Ni and Ni 20Cr model alloy were corroded in molten ZnCl2 and KCl-MgCl2 under argon atmosphere at various temperatures. Oxidation states of Cr (Cr3+) and Ni (Ni2+) in the molten salt after corrosion were determined by monitoring changes in the L2,3 edges of corresponding EELS spectra. Oxidation state mapping technique using principal component analysis and multiple linear least squares fitting in HyperSpy Python package was developed.

36 MATERIALS SCIENCE↗

Controlled wetting and spreading of metals on substrates using porous interlayers and related articles

The disclosure generally relates to a method of creating patterned metallic circuits (e.g., silver circuits) on a substrate (e.g., a ceramic substrate). A porous metal interlayer (e.g., porous nickel) is applied to the substrate to improve wetting and adhesion of the patterned metal circuit material to the substrate. The substrate is heated to a temperature sufficient to melt the patterned metal circuit material but not the porous metal interlayer. Spreading of molten metal circuit material on the substrate is controlled by the porous metal interlayer, which can itself be patterned, such as having a defined circuit pattern. Thick-film silver or other metal circuits can be custom designed in complicated shapes for high temperature/high power applications. The materials designated for the circuit design allows for a low-cost method of generating silver circuits other metal circuits on a ceramic substrate.

Nicholas, Jason Dale↗

Synthesizing intermetallic thermoelectric materials using metal flux growth method

With zero energy poverty by 2050 goals, exploring innovative energy technologies is essential. Thermoelectric materials (TEMs) have the potential to harness waste heat and convert it to electricity (e.g., for spacecraft power, sensors, and cryogenic cooling). Two limitations of thermoelectric compounds are their low efficiency and limited pool of materials. Optimizing the efficiency of TEMs is challenging due to the interdependent relationship between electrical and thermal conductivity. A deeper understanding of electronic properties and lattice thermal conductivity is necessary to “understand, predict and ultimately control” the thermoelectric properties of TEMs. Understanding the influence of light-atom-doping and intrinsic defects on the electronic properties of the f-element containing TEMs are important questions that need to be answered to design and synthesize TEMs with optimal parameters. The purpose of this work is to understand how doping f-element based TEMs with light elements, such as carbon and boron, would impact the crystal structure, bond lengths, band gaps, and thermoelectric characteristics. High-quality f¬-element containing intermetallic single crystals are grown in metal flux media. In molten metal flux growth method, one or more low-melting metals such as aluminum, gallium, tin, and bismuth are used in excess as the reaction medium. As these are solution-state reactions, we can use lower temperatures than solid-state reactions and isolate the kinetic products instead of the thermodynamically stable compound. Then these are characterized using X-ray diffraction, scanning electron microscopy, energy dispersive spectroscopy, magnetization, electrical and thermal conductivities, and thermoelectric power.

37 - INORGANIC, ORGANIC, PHYSICAL AND ANALYTICAL C↗

Assessment of dissimilar metal corrosion in molten chloride salt

Dissimilar metal corrosion between high nickel alloys and stainless steel was tested in purified molten chloride salt. Preliminary results have shown that corrosion rates are significantly affected for samples both when electrically connected and isolated. Suggesting that galvanic corrosion as well as non-galvanic dissimilar metal corrosion play a role in corrosion processes for multi component systems. Finally, these results suggest that even if efforts to prevent electrical contact are taken, close proximity of structural materials can still change corrosion rates in molten salt environments.

14 SOLAR ENERGY↗

Development of Industrial Scale Rare Earth Master Alloys from Their Native Oxides for Magnet Production

The objective of the project is to develop an energy-efficient, reduced cost, and single-step critical metal oxide reduction and alloying methodology for the production of NdFeB and SmCo magnets to facilitate the establishment of a sustainable domestic critical materials supply chain. The method consists of an immiscible molten salt flux layer and a higher density molten metal alloy pool (FeB or Co). The rare earth (RE) oxide and a reductant are added to the molten salt layer, where the reductant first strips the oxygen from the rare earth oxide. Subsequently, the separated RE metal diffuses into the molten metal pool below, creating a RE-saturated master alloy. Towards this end, thermodynamic calculations of the reactions between RE oxides, metallic reducing agent, and molten salt bath chemistry have been performed, and the ideal feeds and conditions for extraction and diffusion to produce master alloys were established. Small-scale and scaled experimentation was performed to validate and optimize the feasibility of viable reactions, temperatures, and process conditions with regards to yield, composition, and process efficiency. Finally, full-scale experiments for the production of NdFeB and SmCo magnets were performed, and their performance characteristics were established.

36 MATERIALS SCIENCE↗

Predictive dynamic wetting, fluid–structure interaction simulations for braze run-out

Brazing and soldering are metallurgical joining techniques that use a wetting molten metal to create a joint between two faying surfaces. Here, the quality of the brazing process depends strongly on the wetting properties of the molten filler metal, namely the surface tension and contact angle, and the resulting joint can be susceptible to various defects, such as run-out and underfill, if the material properties or joining conditions are not suitable. In this work, we implement a finite element simulation to predict the formation of such defects in braze processes. This model incorporates both fluid–structure interaction through an arbitrary Eulerian–Lagrangian technique and free surface wetting through conformal decomposition finite element modeling. Upon validating our numerical simulations against experimental run-out studies on a silver-Kovar system, we then use the model to predict run-out and underfill in systems with variable surface tension, contact angles, and applied pressure. Finally, we consider variable joint/surface geometries and show how different geometrical configurations can help to mitigate run-out. This work aims to understand how brazing defects arise and validate a coupled wetting and fluid–structure interaction simulation that can be used for other industrial problems.

36 MATERIALS SCIENCE↗

Highly Efficient Vacuum Smelting of Aluminum

The goal of this SBIR project was to develop and demonstrate an innovative aluminum smelting technology that will significantly increase the range of aluminum alloys that can be manufactured from recycling of scrap aluminum. This will result in reduction of need for primary aluminum with corresponding 95% energy and CO 2 emission benefits. The proposed melting of pre-sorted aluminum alloys using UHV’s patented high throughput sorter funded by ARPA-E METALS program in an energy efficient vacuum furnace avoids the typical 5% metal loss due to oxidation of molten metal. In addition, pre-sorting scrap into different categories (cast, wrought, extrusion and aerospace) allows lower cost production of high value aluminum alloys without the need for adding alloying elements to primary aluminum. During this SBIR project, pure aluminum and several different commercial alloys were procured and melted in a laboratory furnace in vacuum, CH4 and air environments. The slag and oxidation formation were measured using weight and cross-sectional scanning electron microscope. The results otained were mixed and did not show direct correlation between furnace pressure and oxidation. We believe that the results were tainted due to small furnace size and non-uniformity of oxidation layer. A more thorough investigation is required to prove the advantages of vacuum smelting which could not be performed due to the COVID-19 lockdowns during this project. The theoretical fact remains that in the absence of oxygen in the furnace, there should be no oxide after melting, however the team could not prove it experimentally, and thus decided to dis-continue the project.

36 MATERIALS SCIENCE↗