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DOE OSTI2022

Corrosion of Containment Alloys in Molten Salt Reactors and the Prospect of Online Monitoring

The aim of this review is to communicate some essential knowledge of the underlying mechanism of the corrosion of structural containment alloys during molten salt reactor operation in the context of prospective online monitoring in future MSR installations. The formation of metal halide species and the progression of their concentration in the molten salt do reflect containment corrosion, tracing the depletion of alloying metals at the alloy salt interface will assure safe conditions during reactor operation. Even though the progress of alloying metal halides concentrations in the molten salt do strongly understate actual corrosion rates, their prospective 1 st order kinetics followed by near-linearly increase is attributed to homogeneous matrix corrosion. The service life of the structural containment alloy is derived from homogeneous matrix corrosion and near-surface void formation but less so from intergranular cracking (IGC) and pitting corrosion. Online monitoring of corrosion species is of particular interest for molten chloride systems since besides the expected formation of chromium chloride species CrCl 2 and CrCl 3 , other metal chloride species such as FeCl 2 , FeCl 3 , MoCl 2 , MnCl 2 and NiCl 2 will form, depending on the selected structural alloy. The metal chloride concentrations should follow, after an incubation period of about 10,000 hours, a linear projection with a positive slope and a steady increase of <1 ppm per day. During the incubation period metal concentration show 1 st order kinetics and increasing linearly with time. Ideally, a linear increase reflects homogeneous matrix corrosion, while a sharp increase in the metal chloride concentration could set a warning flag for potential material failure within the projected service life, e.g. as result of intergranular cracking or pitting corrosion. Continuous monitoring of metal chloride concentrations can therefore provide direct information about the mechanism of the ongoing corrosion scenario and offer valuable information for a timely warning of prospective material failure.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1972

Micrometeorite craters on lunar glass particles - The relationship between radial fracture zones and spall zones.

Discussion of the microimpact-crater morphology observed by scanning electron microscopy on a glass bead (nearly 580 microns in maximum diameter) recovered from zone A of the Luna 16 sample. The microcrater has a diameter of approximately 200 microns and a centrally located melted region or pit that is slightly elevated above the surrounding area. Around the pit is a radial fracture zone half of which has spalled off. The spall zone is more than half again as large as the radial fracture zone.

Glass, B. P.↗

NASA NTRS1975

A Life Study of Ausforged, Standard Forged and Standard Machined AISI M-50 Spur Gears

Tests were conducted at 350 K (170 F) with three groups of 8.9 cm (3.5 in.) pitch diameter spur gears made of vacuum induction melted (VIM) consumable-electrode vacuum-arc melted (VAR), AISI M-50 steel and one group of vacuum-arc remelted (VAR) AISI 9310 steel. The pitting fatigue life of the standard forged and ausforged gears was approximately five times that of the VAR AISI 9310 gears and ten times that of the bending fatigue life of the standard machined VIM-VAR AISI M-50 gears run under identical conditions. There was a slight decrease in the 10-percent life of the ausforged gears from that for the standard forged gears, but the difference is not statistically significant. The standard machined gears failed primarily by gear tooth fracture while the forged and ausforged VIM-VAR AISI M-50 and the VAR AISI 9310 gears failed primarily by surface pitting fatigue. The ausforged gears had a slightly greater tendency to fail by tooth fracture than the standard forged gears.

Townsend, D. P.↗

NASA NTRS1975

A life study of ausforged, standard forged, and standard machined AISI M-50 spur gears

Tests were conducted at 350 K with three groups of 8.9 cm pitch diameter spur gears made of vacuum-induction melted (VIM), vacuum-arc remelted (VAR), AISI M-50 steel and one group of vacuum-arc remelted (VAR) AISI 9310 steel. The pitting fatigue life of the standard forged and ausforged gears was approximately five times that of the VAR AISI 9310 gears and ten times that of the bending fatigue life of the standard machined VIM-VAR AISI M-50 gears run under identical conditions. There was a slight decrease in the 10-percent life of the ausforged gears from that for the standard forged gears. However, the difference is not statistically significant. The standard machined gears failed primarily by gear tooth fracture while the forged and ausforged VIM-VAR AISI M-50 and the VAR AISI 9310 gears failed primarily by surface pitting fatigue. The ausforged gears had a slightly greater tendency to fail by tooth fracture than the standard forged gears.

Townsend, D. P.↗

NASA NTRS1976

Microcraters formed in hot glass by hypervelocity projectiles

Microcraters were formed in heated soda-lime glass by the normal incidence of spheres of plastic or fused silica with diameters between 0.8 and 4.5 microns and velocities between 2.5 and 10 km/s. The morphology of the craters in targets at temperatures up to 800 C is little different from those formed in unheated glass. Spallation still occurs to the same extent and above the same velocity threshold, but the spalls sag and sharp edges become dull in a few seconds at temperatures above the softening point. There is a small increase in the flow of glass from the central pit into a narrow lip at the higher temperatures, but this lip is often removed by spallation, especially at the higher velocities of impact. There is no evidence of a splashed lip with strings of melt overlying the spalled area. The results in conjunction with other evidence suggest that most lunar craters of micrometer size with a smooth central pit, splashed lip, and a spallation zone are the result of primary impacts.

Vedder, J. F.↗

NASA NTRS1976

Solid-state growth of Si to produce planar surfaces

Paralleling the sophisticated control of Si and GaAs growth from fluid media, we demonstrate control of Si growth using a solid growth medium. Faceted dissolution pits were first produced in a Si substrate using standard photolithographic techniques and Al metallization. Si was then evaporated onto the cold structure, depositing as amorphous material. Upon heating, the amorphous Si migrated through the solid Al and grew rapidly in the faceted pits, typically refilling them flush with the surrounding substrate. Evidence that the rapid growth occurs only while the amorphous Si is dissolving into the Al is presented.

Boatright, R. L.↗

NASA NTRS1979

Photopolarimetry of scattering surfaces and their interpretation by computer model

Wolff's computer model of a rough planetary surface was simplified and revised. Close adherence to the actual geometry of a pitted surface and the inclusion of a function for diffuse light resulted in a quantitative model comparable to observations by planetary satellites and asteroids. A function is also derived to describe diffuse light emitted from a particulate surface. The function is in terms of the indices of refraction of the surface material, particle size, and viewing angles. Computer-generated plots describe the observable and theoretical light components for the Moon, Mercury, Mars and a spectrum of asteroids. Other plots describe the effects of changing surface material properties. Mathematical results are generated to relate the parameters of the negative polarization branch to the properties of surface pitting. An explanation is offered for the polarization of the rings of Saturn, and the average diameter of ring objects is found to be 30 to 40 centimeters.

Wolff, M.↗

NASA NTRS1980

Endurance and failure characteristics of modified Vasco X-2, CBS 600 and AISI 9310 spur gears

Gear endurance tests and rolling-element fatigue tests were conducted to compare the performance of spur gears made from AISI 9310, CBS 600 and modified Vasco X-2 and to compare the pitting fatigue lives of these three materials. Gears manufactured from CBS 600 exhibited lives longer than those manufactured from AISI 9310. However, rolling-element fatigue tests resulted in statistically equivalent lives. Modified Vasco X-2 exhibited statistically equivalent lives to AISI 9310. CBS 600 and modified Vasco X-2 gears exhibited the potential of tooth fracture occurring at a tooth surface fatigue pit. Case carburization of all gear surfaces for the modified Vasco X-2 gears results in fracture at the tips of the gears.

Townsend, D. P.↗

NASA NTRS1980

Quantitative analysis of defects in silicon. Silicon sheet growth development for the large are silicon sheet task of the low-cost solar array project

One hundred and seventy four silicon sheet samples were analyzed for twin boundary density, dislocation pit density, and grain boundary length. Procedures were developed for the quantitative analysis of the twin boundary and dislocation pit densities using a QTM-720 Quantitative Image Analyzing system. The QTM-720 system was upgraded with the addition of a PDP 11/03 mini-computer with dual floppy disc drive, a digital equipment writer high speed printer, and a field-image feature interface module. Three versions of a computer program that controls the data acquisition and analysis on the QTM-720 were written. Procedures for the chemical polishing and etching were also developed.

Natesh, R.↗

NASA NTRS1980

Tissue response to peritoneal implants

Peritoneal implants were fabricated from poly 2-OH, ethyl methacrylate (HEMA), polyetherurethane (polytetramethylene glycol 1000 MW, 1,4 methylene disocynate, and ethyl diamine), and untreated and sputter treated polytetrafluoroethylene (PTFE). The sputter treated PTFE implants were produced by an 8 cm diameter argon ion source. The treated samples consisted of ion beam sputter polished samples, sputter etched samples (to produce a microscopic surface cone texture) and surface pitted samples (produced by ion beam sputtering to result in 50 microns wide by 100 microns deep square pits). These materials were implanted in rats for periods ranging from 30 minutes to 14 days. The results were evaluated with regard to cell type and attachment kinetics onto the different materials. Scanning electron microscopy and histological sections were also evaluated. In general the smooth hydrophobic surfaces attracted less cells than the ion etched PTFE or the HEMA samples. The ion etching was observed to enhance cell attachment, multinucleated giant cell (MNGC) formation, cell to cell contact, and fibrous capsule formation. The cell responsed in the case of ion etched PTFE to an altered surface morphology. However, equally interesting was the similar attachment kinetics of HEMA verses the ion etched PTFE. However, HEMA resulted in a markedly different response with no MNGC's formation, minimal to no capsule formation, and sample coverage by a uniform cell layer.

Picha, G. J.↗

NASA NTRS1980

Endurance and failure characteristics of modified Vasco X-2, CBS 600 and AISI 9310 spur gears

Townsend, D. P.↗

NASA NTRS1982

Analysis of defect structure in silicon. Silicon sheet growth development for the large area silicon sheet task of the Low-Cost Solar array Project

One hundred ninety-three silicon sheet samples, approximately 880 square centimeters, were analyzed for twin boundary density, dislocation pit density, and grain boundary length. One hundred fifteen of these samples were manufactured by a heat exchanger method, thirty-eight by edge defined film fed growth, twenty-three by the silicon on ceramics process, and ten by the dendritic web process. Seven solar cells were also step-etched to determine the internal defect distribution on these samples. Procedures were developed or the quantitative characterization of structural defects such as dislocation pits, precipitates, twin & grain boundaries using a QTM 720 quantitative image analyzing system interfaced with a PDP 11/03 mini computer. Characterization of the grain boundary length per unit area for polycrystalline samples was done by using the intercept method on an Olympus HBM Microscope.

Natesh, R.↗

NASA NTRS1982

Acoustic microscopy of silicon carbide materials

It is shown that scanning laser acoustic microscopy (SLAM) is able to detect such fracture-controlling flaws in dense silicon carbide materials as surface voids, whose diameter-by-depth size is a minimum of 75 by 17 microns in reaction-bonded SiC and 68 by 25 microns in alpha-SiC. Surface conditions such as pitting, which have been found to limit the discernibility of drilled holes, become important when pit and drilled hole sizes become comparable.

Khandelwal, P. K.↗

NASA NTRS1981

On the cause of the flat spot phenomenon observed in silicon solar cells at low temperatures and low intensities

The results of an effort to determine the mechanisms involved in the flat spot (FS) effect are given. It is suggested that the FS effect is due to a resistive metal-semiconductor-like (MSL) interface in parallel with the cell PN junction. Regions responsible for the FS effect lie under the front surface metallization in these cells, where the PN junction has been destroyed and replaced with a metal silicide-semiconductor interface. Such structural changes, which appear to be due to the thermally activated dissolution of the silicon, have been induced in cells as a result of isochronal heat treatments at temperatures between 450 C and 560 C. It has been found that a 650 A layer of Ta2O5 evaporated over the metallization is sufficient to prevent the underlying silicon from pitting during the subsequent heat treatment, although pitting at the metal silicon ambient interface could still be observed.

Weizer, V. G.↗

NASA NTRS1982

Oceanic corrosion test of bare and zinc-protected aluminum alloys for seawater heat exchangers

Bare 3004 tubes, 7072 Alclad 3004 tubes, and bare and zinc diffusion treated 3003 extrusions from a brazed aluminum, plate-fin heat exchanger were exposed to 1.8 m/sec flowing seawater aboard an open ocean test facility moored 3.4 km off the southeast coast of Puerto Rico. After six months exposure, the average corrosion rates for most varieties of aluminum materials converged to a low value of 0.015 mm/yr (0.6 mils/yr). Pitting did not occur in bare 3003 and 3004 samples during the six month test. Pitting did occur to varying degrees in the Alclad and zinc diffusion treated material, but did not penetrate to the base metal. Biofouling countermeasures (intermittent chlorination and brushing) did not affect the corrosion rates to any significant extent. Intermittent chlorination at a level of 0.5 ppm for 28 minutes daily controlled microbiofouling of the samples but did not prevent the development of a macrobiofouling community in areas of the plumbing with low flow.

Sasscer, D. S.↗

NASA NTRS1983

Corrosion of simulated bearing components of three bearing steels in the presence of chloride-contaminated lubricant

Corrosion tests were run with AISI 52100, AISI M-50 and AMS 5794 under conditions that simulate the crevice corrosion found in aircraft ball and roller bearings rejected at overhaul for corrosion. Test specimens were fabricated that simulated the contacts of balls or rollers and the raceways. Corrosion cells were assembled in the presence of a lubricant contaminated with water and chloride ions. The cell was then thermally cycled between 339 K (150 F) and 276 K (37 F). The corrosion observed after 14 cycles was that of crevice and pitting corrosion typically found in aircraft bearings. AMS 5749 showed a very slight amount of corrosion. No appreciable differences were noted between AISI 52100 and AISI M-50, but both showed much greater corrosion than AMS 5749. The corrosion pits observed in AISI M-50 appeared to be fewer in number but generally deeper and larger than in AISI 52100.

Parker, R. J.↗

NASA NTRS1983

Cavitation Erosion of Copper, Brass, Aluminum and Titanium Alloys in Mineral Oil

The variations of the mean depth of penetration, the mean depth rate of penetration, MDRP, the pit diameter 2a and depth h due to cavitation attack on Al 6061-T6, Cu, brass of composition Cu-35Zn-3Pb and Ti-5A1-2.5Sn are presented. The experiments are conducted in a mineral oil of viscosity 110 CS using a magnetostrictive oscillator of 20 kHz frequency. Based on MDRP on the materials, it is found that Ti-5Al-2.5Sn exhibits cavitation erosion resistance which is two orders of magnitude higher than the other three materials. The values of h/a are the largest for copper and decreased with brass, titanium, and aluminum. Scanning electron microscope studies show that extensive slip and cross slip occurred on the surface prior to pitting and erosion. Twinning is also observed on copper and brass.

Rao, B. C. S.↗

NASA NTRS1982

Craters and basins on Ganymede and Callisto - Morphological indicators of crustal evolution

The morphologic characteristics of craters and palimpsests on Ganymede and Callisto are surveyed, and the crustal properties of these satellites and the evolution of the properties are studied. The morphology of bowl-shaped craters, smooth-floored craters, craters without central peaks, craters with central pits, chain craters on Callisto, the Gilgamesh and Western Equatorial Basins on Ganymede, crater palimpsests and penepalimpsests, multiring structures on Callisto, and the Galileo Regio rimmed furrow system on Ganymede are described individually. The crustal evolution is addressed by examining the development of the Galileo Regio system, the distribution of crater retention ages, the record of ray clusters, the thermal history of the lithosphere of Ganymede, and the origin of the central pits. It is suggested that as the lithosphere of each satellite cooled and thickened, crater retentivity spread as a wave from the polar regions and the antapex toward the apex; at any given location, progressively larger craters were retained with the passage of time.

Passey, Q. R.↗