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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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31 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Molecular Iodine Interactions with Metal Substrates: Towards the Understanding of Iodine Interactions in the Environment Following a Nuclear Accident

In order to evaluate the potential impacts to the public from radioiodine in a nuclear event, it is vital to expand our understanding of the interaction of molecular iodine with various surfaces. There are many potential surfaces that iodine could interact with in and around a nuclear facility, including stainless steel. This study, carried out at ambient temperature, pressure and humidity, demonstrates the highly adsorptive nature of molecular iodine on two types of austenitic stainless steel, 304L and 316L. In the authors review of available literature, Fe is the only metal in stainless steel that is assumed to react with gas-phase molecular iodine. By using a novel approach which combines Inductively Coupled Plasma-Optical Emission Spectroscopy (ICP-OES) with surface Energy Dispersive X-ray Spectroscopy (EDS) there is evidence of the formation of metal iodides that have not previously been verified or quantified. Samples exposed to gaseous molecular iodine formed an iodine containing corrosion product visible by scanning electron microcopy (SEM). Evaluation of the metals in the corrosion region using EDS was compared to a water leach of the same samples analyzed using ICP-OES. A comparison of the results provide evidence that the water leachate is representative of the corrosion layer and not the base material. Furthermore, it provides confirmation of metal iodide formation with minor stainless-steel constituents including: FeI2, NiI2, MnI2 and CrI2.

Beck, Chelsie L.↗
DOE OSTI2020

Effect of microstructural and environmental variables on ductility of austenitic stainless steels

Austenitic stainless steels are used extensively in harsh environments, including for high-pressure gaseous hydrogen service. However, the tensile ductility of this class of materials is very sensitive to materials and environmental variables. While tensile ductility is generally insufficient to qualify a material for hydrogen service, ductility is an effective tool to explore microstructural and environmental variables and their effects on hydrogen susceptibility, to inform understanding of the mechanisms of hydrogen effects in metals, and to provide insight to microstructural variables that may improve relative performance. In this study, hydrogen precharging was used to simulate high-pressure hydrogen environments to evaluate hydrogen effects on tensile properties. Several austenitic stainless steels were considered, including both metastable and stable alloys. Room temperature and subambient temperature tensile properties were evaluated with three different internal hydrogen contents for type 304L and 316L austenitic stainless steels and one hydrogen content for XM-11. Significant ductility loss was observed for both metastable and stable alloys, suggesting the stability of the austenitic phase is not sufficient to characterize the effects of hydrogen. Internal hydrogen does influence the character of deformation, which drives local damage accumulation and ultimately fracture for both metastable and stable alloys. While a quantitative description of hydrogen-assisted fracture in austenitic stainless steels remains elusive, these observations underscore the importance of the hydrogen-defect interactions and the accumulation of damage at deformation length scales.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Fatigue and Fracture Behavior of Additively Manufactured Austenitic Stainless Steel

Additive manufacturing (AM) includes a diverse suite of innovative manufacturing processes for producing near-net shape components, typically from powder or wire feedstock. Reported mechanical properties of AM materials vary significantly depending on the details of the manufacturing process and the characteristics of the processing defects (namely, lack of fusion defects). However, an excellent combination of strength, ductility and fracture resistance can be achieved in AM type 304L and 316L austenitic stainless steels by minimizing processing defects. It is also important to recognize that localized solidification processing during AIVI produces microstructures more analogous to weld microstructures than wrought microstructures. Consequently, the mechanical behavior of AM austenitic stainless steels in harsh environments can diverge from the performance of wrought materials. This report gives an overview of the fracture and fatigue response of type 304L materials from both directed energy deposition (DED) and powder bed fusion (PBF) techniques. In particular, the mechanical performance of these materials is considered for high-pressure hydrogen applications by evaluating fatigue and fracture resistance after thermally precharging of test specimens in high-pressure gaseous hydrogen. The mechanical behaviors are considered with respect to previous reports on hydrogen-assisted fracture of austenitic stainless steel welds and the unique characteristics of the AM microstructures. Fatigue crack growth can be relatively insensitive to processing defects, displaying similar behavior as wrought materials. Fracture resistance of dense AM austenitic stainless steel, on the other hand, is more consistent with weld metal than with compositionally-similar wrought materials. Hydrogen effects in the AM materials are generally more severe than in wrought materials, but comparable to measurements on welded austenitic stainless steels in hydrogen environments. While hydrogenassisted fracture manifests differently in welded and AM austenitic stainless steel, the fracture process appears to have a common origin in the compositional microsegregation intrinsic to solidification processes.

additive manufacturing, austenitic stainless steel↗
DOE OSTI2021

Corrosion of Ferrous Structural Alloys in Biomass Derived Fuels and Organic Acids

This work investigated the corrosivity of biomass-derived liquid fuels and organic acids associated with bio-oils and conducted a corrosion compatibility evaluation of several structural ferrous alloys in the fuels and acids. Here, the acidity parameters and solution conductivity values were higher in raw pyrolysis bio-oils than postprocessed oils with significant corrosion attack for carbon steel and Fe-2.25Cr-1Mo. However, higher-grade stainless steels, ferritic Fe-15Cr (15Cb) and austenitic types 304L and 316L, showed negligible corrosion loss, whereas lower-Cr ferritic grades 409, 410, and 416 were attacked. Metal leaching tests and electrochemical impedance spectroscopy measurements revealed superior corrosion resistance of 316 over 410 stainless steels in solutions of formic and oxalic acids that can be present in bio-oils. The corrosion evaluation methods utilized in this work provide effective screening tools to identify the compatible structural alloys for bio-oils.

09 BIOMASS FUELS↗
DOE OSTI2023

FY23 Simulation of Elastic-Plastic Failure Propagation

This memo summarizes the simulation of ductile failure propagation work conducted under the ASC project “V&V of Ductile Failure” conducted during FY 23. Physically, the failure propagation consists of crack propagation in the material. In the numerical setting—specifically in a finite element model—propagation can be accomplished through element death when critical conditions occur locally at an element that is then deleted from the simulation. The validation of the finite element models is evaluated by direct comparison between the experimental and simulation results regarding the rate of crack growth and its influence on the load-deflection response of the specimens tested. This work considers two geometries that display stable crack propagation under displacement-controlled conditions. The first geometry consists of hat specimens loaded in compression with nominally identical geometries but made with three different materials: Steel A286, Al 7075-T651 and 304L stainless steel. The three materials represent a range of ductility values that affect the response and crack propagation within the specimen. The crack induced propagates under an essentially mode-II type of deformation. The second geometry consists of a pre-cracked 304L stainless steel compact tension test specimen loaded so as to induce a mode-I deformation at the crack.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Cold Spray Deposition of 304L Stainless Steel to Mitigate Chloride-Induced Stress Corrosion Cracking in Canisters for Used Nuclear Fuel Storage

A feasibility study of the cold spray deposition process of 304L stainless steel on 304L stainless steel substrates as a mitigation method for chloride-induced stress corrosion cracking (CISCC) has been investigated under various substrate conditions. The study is aimed at the application of this technology to mitigate CISCC that may potentially occur in or nearthe fusion welded regions of stainless steel canisters in Dry Cask Storage System (DCSS) for used nuclear fuels. Spherical gas-atomized 304L stainless steel powder, in the size range of 25 µm to 44 µm, was used as a feedstock powder for the cold spray process. The powder was deposited on four types of 304L substrates with various surface conditions: as-polished, oxidized, cold-rolled, plates with prototypical CISCC. The effects of cold spray parameters on quality of cold spray coatings were investigated. Thickness, porosity, and phases in the as-deposited materials were evaluated using scanning electron microscopy (SEM) and X-ray diffraction (XRD), and correlated with microhardness and adhesion strength measured via micro-indentation and ASTM C633 pulling test, respectively. XRD analysis of the coatings was also conducted to examine the effects of cold spray condition on residual stress state in the coating. Detailed cross-sectional examination of coating/substrate interfaces was performed with transmission electron microscopy (TEM) equipped with energy dispersive spectroscopy (EDS). Dense and continuous coatings with good adhesion strength and hardness were produced for the various substrate conditions by adjusting cold spray parameters. The results demonstrate that cold spray stainless steel coating is a viable option to provide a physical barrier against CISCC in fusion weld regions of stainless steel in corrosive chloride salt-bearing environments.

Dry Cask Storage Systems, cold spray, 304L stainle↗
DOE OSTI2023

Experimental and Computational Studies of Stress Corrosion Cracking of Alloys 308/309 and 82/182 Weldments in Corrosive and Radiation Environment

The goal of the project was to determine factors that influence SCC and IASCC in weldments found in LWR nuclear power plants. We focused on a SA508-304L SS weldment fabricated by EPRI using gas tungsten arc welding and used an aggressive BWR normal water chemistry (NWC) immersion environment. This weldment used 309L butter and 308L groove filler material. The microstructure of the 309L butter was non-uniform, exhibiting a 20–30μm thick martensitic layer closest to the SA508 interface, a 1–4 mm thick single γ austenite phase dilution zone, and a γ–δ duplex region extending to the 308L groove filler. The 308L groove filler had an entirely γ–δ duplex microstructure. Two approximately 1-inch thick 304L and SA508 plates approximately 12 by 6 square inches were joined using standard nuclear grade welding techniques. This included a post weld heat treatment of the 309L butter after application, a 0.32 cm fit-up root opening, and 57 bead lines of 308L groove filler applied in 18 layers. A 60 degree weld bevel angle was used and the 309L butter was 1.5 cm thick. Displacement cascade damage was induced using proton irradiation at the Michigan Ion Beam Laboratory. The incident proton energy was 2 MeV, the sample temperature was 360 ºC, and the calculated dpa value at 10 μm (60% of the Bragg peak depth of ~18 μm) was 5 dpa using the quick Kinchin-Pease model. Proton irradiation to this damage level required approximately 125 hours of beam time. Two types of samples were irradiated, tensile specimens and TEM bars. Samples were selected from all regions of the weldment, including the SA508-309L butter interface, the 309L-308L interface, and 308L-304L interface. The stainless steel alloys (304L, 308L, and 309L) within the heat affected zone are characterized by a duplex skeletal morphology of δ-ferrite and γ-austenite resulting from the recrystallization associated with weld fabrication. Approximately 7 to 8 mm of length along the specimen was irradiated. The gauge volume surfaces were mechanically polished and then electro-polished to remove mechanical damage from the mechanical polishing step prior to irradiation. Immersion tests were performed in a recirculating autoclave under BWR NWC conditions (2000 ppb wt. dissolved oxygen, neutral pH, 288 ºC, 10 MPa, and inlet water conductivity <100 nS/cm) to accelerate corrosion. Constant strain rate tests were performed either to failure or to approximately 5% strain. Strain rates of 10 -7 to 10 -6 mm/mm/s were used and typical immersion testing required four to six weeks to achieve failure or strains near 5%. Analysis primarily used advanced electron microscopy techniques of FIB lift out specimens.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1975

Environmental crack-growth behavior of high strength pressure vessel alloys

Results of sustained-load environmental crack growth threshold tests performed on six spacecraft pressure vessel alloys are presented. The alloys were Inconel 718, 6Al-4V titanium, A-286 steel, AM-350 stainless steel, cryoformed AISI 301 stainless steel; and cryoformed AISI 304L steel. The test environments for the program were air, pressurized gases of hydrogen, oxygen, nitrogen, and carbon dioxide, and liquid environments of distilled water, sea water, nitrogen tetroxide, hydrazine, aerozine 50, monomethyl hydrazine, and hydrogen peroxide. Surface flaw type specimens were used with flaws located in both base metal and weld metal.

Forman, R. G.↗
NASA NTRS1973

Fundamental study of transpiration cooling

Isothermal and non-isothermal pressure drop data and heat transfer data generated on porous 304L stainless steel wire forms, sintered spherical stainless steel powder, and sintered spherical OFHC copper powder are reported and correlated. Pressure drop data was collected over a temperature range from 500 R to 2000 R and heat transfer data collected over a heat flux range from 5 to 15 BTU/in2/sec. It was found that flow data could be correlated independently of transpirant temperature and type (i.e., H2, N2). It was also found that no simple relation between heat transfer coefficient and specimen porosity was obtainable.

Koh, J. C. Y.↗
DOE OSTI2022

Crystallographic effects on transgranular chloride-induced stress corrosion crack propagation of arc welded austenitic stainless steel

Abstract The effect of crystallography on transgranular chloride-induced stress corrosion cracking (TGCISCC) of arc welded 304L austenitic stainless steel is studied on >300 grains along crack paths. Schmid and Taylor factor mismatches across grain boundaries (GBs) reveal that cracks propagate either from a hard to soft grain, which can be explained merely by mechanical arguments, or soft to hard grain. In the latter case, finite element analysis reveals that TGCISCC will arrest at GBs without sufficient mechanical stress, favorable crystallographic orientations, or crack tip corrosion. GB type does not play a significant role in determining TGCISCC cracking behavior nor susceptibility. TGCISCC crack behaviors at GBs are discussed in the context of the competition between mechanical, crystallographic, and corrosion factors.

36 MATERIALS SCIENCE↗
NASA NTRS1974

Dissimilar metals joint evaluation

Dissimilar metals tubular joints between 2219-T851 aluminum alloy and 304L stainless steel were fabricated and tested to evaluate bonding processes. Joints were fabricated by four processes: (1) inertia (friction) weldings, where the metals are spun and forced together to create the weld; (2) explosive welding, where the metals are impacted together at high velocity; (3) co-extrusion, where the metals are extruded in contact at high temperature to promote diffusion; and (4) swaging, where residual stresses in the metals after a stretching operation maintain forced contact in mutual shear areas. Fifteen joints of each type were prepared and evaluated in a 6.35 cm (2.50 in.) O.D. size, with 0.32 cm (0.13 in.) wall thickness, and 7.6 cm (3.0 in) total length. The joints were tested to evaluate their ability to withstand pressure cycle, thermal cycle, galvanic corrosion and burst tests. Leakage tests and other non-destructive test techniques were used to evaluate the behavior of the joints, and the microstructure of the bond areas was analyzed.

Wakefield, M. E.↗
DOE OSTI2024

All-digital Sensor System for Distributed Downhole Pressure Monitoring in Unconventional Fields

This project developed and validated (through field tests) a new low-cost all-digital pressure sensing technology for in situ distributed downhole pressure monitoring in unconventional oil and gas (UOG) fields. The all-digital sensing technology uses a built-in non-electric analog-to-digital converter (ADC) to transform the pressure information into a combination of binary (ON/OFF) states. As such, the system does not need downhole electronics for signal conditioning and telemetry. The all-digital sensors can be remotely logged over a long distance, and many sensors can be multiplexed for distributed sensing. Based on a review of unconventional wells in the Lower 48 states, the specification of the sensor is to measure pressure up to 69 MPa (10,000 psi) and temperature up to 250°C. A sensor with a helical bourdon sensing element and a digital signal decoder of 50 mm diameter and 109 mm length was constructed. The helical bourdon sensing element was made of 304L stainless steel and filled with motor oil. The digital converter was made up of 8 digital reading pads constructed of high-temperature epoxy with conductive inserts made of stainless steel. The sensor had a linear response to pressure with an accuracy of 0.14 MPa (20 psi). To withstand the high pressure, the sensor was enclosed in a stainless-steel pressure housing with a wall thickness of 5.5 mm, a diameter of 73 mm, and a length of 724 mm. In the laboratory tests, the sensor exhibited no temperature-related effects on the results. The sensor did not show drift over a 14-day test period at elevated pressure. A field test was conducted where the sensor was deployed in a test wellbore at the Quest drilling test facility to a depth of 0 feet over three weeks. The sensor was attached to the production rods, along with a downhole reference sensor of PPS27 type, which is a permanent downhole monitoring system. During the testing phase, the test well annular blow-out preventer was closed, and the well was pressurized at the surface to 11 MPa (1600 psi). The sensor read the elevated bottom hole pressure of 1500 psi. A multiplexing unit was created for the sensor to deploy multiple sensors on one data transmission line in a distributed approach. The multiplexing unit was tested in a simulated environment of 3048 m (10,000 ft) with five sensors distributed. The sensors were pressurized at different intervals. The multiplexed sensors recorded the correct pressure, and the multiplexing did not interfere with the readings. The proposed concept of an all-digital pressure sensor for harsh downhole environments was designed, manufactured, and tested in the laboratory and tested at the field to a up to 69 MPa and 250°C. This technology has high-temperature tolerance and has potential in downhole areas outside oil and gas, such as carbon capture and storage (CCS) and geothermal wells. The sensor concept has been proven in this project, but to create a commercially viable product, manufacturing a sensor with a smaller diameter needs to be performed.

02 PETROLEUM↗
DOE OSTI2024

Dissolution Flowsheet for Non-Aluminum Spent Nuclear Fuel Campaign 1

As part of the Accelerated Basin De-inventory (ABD) program, H Canyon plans to dissolve non-aluminum spent nuclear fuel (NASNF) in the 6.3D electrolytic dissolver. NASNF Campaign 1 plans to electrolytically dissolve 68 bundles of fuel assemblies from the Carolinas-Virginia Tube Reactor (CVTR), Heavy Water Components Test Reactor (HWCTR), and Experimental Boiling Water Reactor (EBWR). The fuel assemblies are intact Zircaloy or stainless steel (SS) clad UO 2 rods, tubes, and plates. The H Canyon electrolytic dissolver previously dissolved a variety of UO 2 core fuel types in SS, Zircaloy, Nichrome, or Incoloy cladding from 1969 to 1980. The objective of this study was to identify flowsheet conditions through literature review and laboratory experimentation to safely dissolve NASNF Campaign 1 bundles in the H Canyon electrolytic dissolver. Bench-scale electrolytic dissolution tests were performed to demonstrate a flowsheet for NASNF Campaign 1 bundles. The outer bundles are composed of SS or Al alloy, Al 6061-T6, and contain intact Zircaloy or SS clad UO 2 fuel assemblies. The key objectives of these tests were to determine bounding dissolver chemistries and the sparge requirement to ensure H 2 concentration remain less than 60 vol % of the lower flammability limit (LFL) during dissolution. The impact of HNO 3 concentration and the addition of fluoride on the dissolution efficiency of Zircaloy, 304L SS, Al 6061-T6, and Inconel 625 were examined. While SS, Al, and Inconel 625 readily dissolve utilizing electrolytic dissolution, Zircaloy disintegrated anodically; the surface of Zircaloy oxidized and the oxide layer spalled off and settled at the bottom of the dissolver as an insoluble material. The black flakes were identified as ZrO 2 and 85% of the Zr processed was converted to black ZrO 2 flakes when Zr was anodically disintegrated in 9.5 M HNO 3 .

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗