Search NASA⌕ Search

SEARCH · Search NASA

Results for “surface alloying”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 433 records · Page 24
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Development of Corrosion- and Erosion-Resistant Coatings for Advanced Ultra-Supercritical Materials

This final report summarized the research efforts and major findings of the Phase I Project “Development of Corrosion- and Erosion-Resistant Coatings for Advanced Ultra-Supercritical Materials”, for the period of October 1, 2019 – Sept. 30, 2021. This project is a collaborative endeavor between Tennessee Tech University, Purdue University, Oak Ridge National Laboratory, Siemens Corporation, and Eastern Plating, LLC, aiming at improving the durability and lifetime of high-pressure (HP) steam turbine blades in advanced ultra-supercritical (A-USC) coal-fired power plants through the development of corrosion/erosion-resistant coatings manufactured via a low-cost electrolytic codeposition process. While Tribaloy alloy T-400C was identified by the U.S. A-USC Materials Consortium as a promising coating composition, further composition optimization is needed to enhance its corrosion and erosion resistance for protecting the A-USC Ni-base turbine components. An integrated computational and experimental approach was employed to optimize coating composition/microstructure and processing parameters. In order to identify candidate coating compositions that could offer balanced properties, thermodynamic calculations were performed to explore the γ+Laves composition space in the Co-Ni-Cr-Mo-Si system with different alloying additions at 600-800 °C. Guided by the calculation results, experimental assessment of selected alloys led to the development of a new generation of Tribaloy compositions with the optimal levels of Cr, Mo and Si, reactive element (e.g., 0.4-0.6 wt.% Y) and other alloying additions. The low-cost and non-line-of-sight electro-codeposition process was employed to deposit a Ni(Co)-CrMoSiY composite coating on commercial Haynes 282 (H282) Ni-base alloy. A diffusion treatment was subsequently applied to convert the composite to the Tribaloy-type coating. Both the codeposition parameters and heat treatment conditions were varied to achieve the desired coating composition, microstructure and phase constituents. In addition, since additive manufacturing (AM) may be an alternative cost-saving option for potential A-USC turbine repair, laser direct deposition was explored to fabricate the H282 alloy with minimal defects. The electro-codeposited Tribaloy coating was also applied to the AM H282 substrate to demonstrate the viability of the coating process in improving the surface finish of AM alloys. Both high-temperature oxidation performance and solid particle erosion (SPE) resistance of model alloys and electro-codeposited coatings were evaluated. About 25 model alloys with various Cr/Mo ratios and reactive element levels, as well as partial substitution of Mo with Nb were evaluated with regard to their oxidation resistance in both air and pure steam at 760-800°C. Compositions based on Ni(Co)-20Cr-18Mo-2.6Si-0.6Y (wt.%) showed significantly improved oxidation resistance over the baseline T400-C. Based on the alloy development results, three generations of new Tribaloy coatings (Gen-1, Gen-2, and Gen-3) with various Mo/Cr contents and Y levels were prepared via electro-codeposition and their microstructure/performance were evaluated. Outstanding air and steam oxidation resistance was achieved for the Gen-2 and Gen-3 coatings. Furthermore, while the SPE resistance of the coatings depended on many factors such as temperature, environment, erodent, velocity and impact angle, the coated samples exhibited similar or better SPE resistance compared to the H282 substrate when magnetite was used as erodent (which is a realistic erodent in A-USC steam turbines). The new Tribaloy coatings also had good long-term compatibility with the H282 alloy substrate. The two large-sized rotating barrels were designed, constructed, and employed to coat dummy HP blades. Uniform coating thickness and microstructure were achieved at various blade locations. Also, a preliminary techno-economic analysis of the proposed coating process was conducted to quantify the cost-effectiveness and to assess the commercial viability of the corrosion- and erosion-resistant coatings. It is estimated that a cost reduction of ~30% could be achieved with the electro-codeposition coating process over the state-of-the-art high velocity oxygen fuel (HVOF) thermal spray. Compared to the leading Tribaloy coating technologies such as HVOF and plasma transfer alloying, electro-codeposition based process has advantages such as low-cost process equipment, uniform deposition even for complex shapes, low levels of contaminants/porosities, reduction of powder waste, and potentially better surface finish and longer turbine service life. The Phase 1 study has demonstrated that it is feasible to develop an electro-codeposited Tribaloy coating with balanced corrosion and erosion properties, even though additional research efforts such as further coating process scale-up and longer-term performance evaluation under realistic A-USC conditions are clearly needed.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2022

Potentiodynamic Polarization of Pure Metals and Alloys in Molten LiF-NaF-KF (FLiNaK) Using the K/K + Dynamic Reference Electrode

The potentiodynamic polarization method using the K/K + dynamic reference electrode was used to understand the corrosion behavior of Ni, Fe, Cr, the Ni-20Cr binary alloy, and 316L stainless steel in molten 46.5LiF-11.5NaF-42KF (FLiNaK, composition in mol %) salt at 700 °C. Exposure of the materials without an applied potential revealed that Ni and Fe were stable in FLiNaK, but Cr was dissolved rapidly. The apparent redox potentials of each material with respect to the K/K + redox couple are compared to gain insight into how the applied potential relates to the dominant corrosion mechanism for each alloy. Furthermore, the polarized pure metals experienced uniform surface recession while corrosion in the alloys resulted in preferential elemental dissolution depending on the applied potential with respect to the K/K + reference reaction.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1976

Fracture analysis of surface and through-cracks in cylindrical pressure vessels

A previously developed fracture criterion was applied to surface- and through-cracked cylindrical pressure vessels to see how well the criterion can correlate fracture data. Fracture data from the literature on surface cracks in aluminum alloy, steel, and epoxy vessels and on through cracks in aluminum alloy, titanium alloy, steel, and brass vessels were analyzed using the fracture criterion. The criterion correlated the failure stresses to within + or - 10 percent for either surface or through cracks over a wide range of crack size and vessel diameter. The fracture criterion was also found to correlate failure stresses from flat plates (center-crack or double-edge-crack tension specimens) and cylindrical pressure vessels containing through - cracks within + or - 10 percent.

Newman, J. C., Jr.↗
NASA NTRS1976

Ion beam sputter modification of the surface morphology of biological implants

The surface chemistry and texture of materials used for biological implants may significantly influence their performance and biocompatibility. Recent interest in the microscopic control of implant surface texture has led to the evaluation of ion beam sputtering as a potentially useful surface roughening technique. Ion sources, similar to electron bombardment ion thrusters designed for propulsive applications, are used to roughen the surfaces of various biocompatible alloys or polymer materials. These materials are typically used for dental implants, orthopedic prostheses, vascular prostheses, and artificial heart components. Masking techniques and resulting surface textures are described along with progress concerning evaluation of the biological response to the ion beam sputtered surfaces.

Weigand, A. J.↗
NASA NTRS1977

Ion-beam-sputter modification of the surface morphology of biological implants

The surface chemistry and texture of materials used for biological implants may significantly influence their performance and biocompatibility. Recent interest in the microscopic control of implant surface texture has led to the evaluation of ion-beam sputtering as a potentially useful surface roughening technique. Ion sources, similar to electron-bombardment ion thrusters designed for propulsive applications, are used to roughen the surfaces of various biocompatible alloys or polymer materials. These materials are typically used for dental implants, orthopedic prostheses, vascular prostheses, and artificial heart components. Masking techniques and resulting surface textures are described along with progress concerning evaluation of the biological response to the ion-beam-sputtered surfaces.

Weigand, A. J.↗
DOE OSTI2022

Significant slowdown of plasma-optimized surface energy deactivation by vacuum sealing for efficient adhesive bonding

This work proposes an approach to minimize surface energy deactivation of plasma-treated metal and carbon fiber-reinforced polymer (CFRP) surfaces by vacuum sealing. Plasma treatments enhance adhesive wettability on post-treated surfaces for adhesive joints, but the treated surfaces deactivate quickly in air. The surface energy of aluminum alloy AA6061 and carbon fiber-reinforced polymer-polyamide (CFRP-PA66) optimally treated by a blown air plasma instrument returns to the original surface energy within one hour. Vacuum sealing of AA6061 and CFRP-PA66 reduced the surface energy deactivation over 7 days by at least 230 times and 970 times compared to in air. Double Cantilever Beam (DCB) tests performed on adhesively-bonded AA6061/CFRP-PA66 joints showed that the total energy release and energy dissipation before failure of plasma-treated and vacuum-sealed materials was up to 60% more than plasma-treated materials without vacuum sealing and up to 125% more than non-plasma-treated materials.

42 ENGINEERING↗
NASA NTRS1976

Fracture analysis of surface and through cracks in cylindrical pressure vessels

A previously developed fracture criterion was applied to fracture data for surface- and through-cracked cylindrical pressure vessels to see how well the criterion can correlate fracture data. Fracture data from the literature on surface cracks in aluminum alloy, steel, and epoxy vessels, and on through cracks in aluminum alloy, titanium alloy steel, and brass vessels were analyzed by using the fracture criterion. The criterion correlated the failure stresses to within + or - 10 percent for either surface or through cracks over a wide range of crack size and vessel diameter. The fracture criterion was also found to correlate failure stresses to within + or - 10 percent for flat plates (center-crack or double-edge-crack tension specimens) and cylindrical pressure vessels containing through cracks.

Newman, J. C., Jr.↗
NASA NTRS1991

Surface effects on hydrogen permeation through Ti-14Al-21Nb alloy

Hydrogen transport through Ti-14Al-21Nb (wt percent) alloy is measured using ultrahigh vacuum permeation techniques over the temperature range of 500 to 900 C and hydrogen pressure range of 0.25 to 10 torr. Hydrogen permeability through the alloy can be described through two different mechanisms depending on th temperature of exposure. In the 675 to 900 C range, the process is diffusion-limited: the permeability has a weak temperature dependence, but the diffusivity has a strong temperature dependence. Below 675 C, the permeation rate of hydrogen is very sensitive to surface controlled processes such as the formation of a barrier layer from contaminants. A physical model explaining the role of surface films on the transport of hydrogen through Ti-14Al-21Nb alloy was described.

Sankaran, Sandara N.↗
NASA NTRS1975

Wear and interfacial transport of material

The paper is a review of adhesion or bonding across an interface between two solids in contact, transfer or transport to one or both surfaces, wear with tangential motion, and the effect of surface films on adhesion, transfer, and wear. The discussion is limited to the case of adhesive wear which deals with the interfacial transport of material from one surface to another. The data presented suggest that the resulting interfacial adhesive bond for metals in contact is generally stronger than the cohesive bond in the cohesively weaker of the two materials so that upon separation of the surfaces transfer will occur from the cohesively weaker material to the cohesively stronger; that with tangential motion of two metal surfaces in contact such as encountered with sliding, rolling, or rubbing contact, the frictional energy can be dissipated in a number of ways, where heating of the surfaces can produce metallurgical changes such as alloying; and that the presence of adsorbed and reacted films on the surface of metals and alloys even in frictions of a monolayer can reduce interfacial bonding, adhesion, and transfer.

Buckley, D. H.↗
DOE OSTI2024

Formation of (Rh–Fe)–FeO x Complex Sites Enables Methanol Synthesis from CO 2

Here, we addressed the challenges of designing catalysts for selective CO 2 hydrogenation by incorporating oxide Fe species onto Rh nanoparticles. Nanoscopic FeO x domains created a “reverse catalyst” structure (i.e., a metal oxide supported on a metal) that increased the density of interfacial sites compared to traditional supported catalysts. The contact between the metal nanoparticle and the oxide overlayer induced the formation of a surface Rh-Fe alloy that stabilize methoxy groups while suppressing hydrogenolysis to methane. Sites at FeO x -metal interfaces interact with CO 2 sevenfold stronger than sites on metal surfaces, show larger energy barriers to cleave the C-O bonds, and offer a barrierless pathway for hydrogenation of methoxy species to methanol. Consequently, the multifunctional sites over FeO x /Rh-Fe catalysts highlight and meet the requirements of a selective methanol catalyst: strong interaction with CO 2 to ensure high density of transition states; metal sites to activate and make hydrogen available to surface intermediates; and high energy barriers for C-O bond cleavage to form carbides. These synthesis and catalytic chemistries, demonstrated for Rh-Fe-FeO x interfaces, enable us to overcome the limitations to the design of methanol production catalysts.

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

Controlling Hydrocarbon (De)Hydrogenation Pathways with Bifunctional PtCu Single-Atom Alloys

The conversions of surface-bound alkyl groups to alkanes and alkenes are important steps in many heterogeneously catalyzed reactions. On the one hand, while Pt is ubiquitous in industry because of its high activity toward C–H activation, many Pt-based catalysts tend to overbind reactive intermediates, which leads to deactivation by carbon deposition and coke formation. On the other hand, Cu binds intermediates more weakly than Pt, but activation barriers tend to be higher on Cu. We examine the reactivity of ethyl, the simplest alkyl group that can undergo hydrogenation and dehydrogenation via β-elimination, and show that isolated Pt atoms in Cu enable low-temperature hydrogenation of ethyl, unseen on Cu, while avoiding the decomposition pathways on pure Pt that lead to coking. Lastly, we confirm the predictions of our theoretical model and experimentally demonstrate that the selectivity of ethyl (de)hydrogenation can be controlled by changing the surface coverage of hydrogen.

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

Surface oxygenation of multicomponent nanoparticles toward active and stable oxidation catalysts

Abstract The need for active and stable oxidation catalysts is driven by the demands in production of valuable chemicals, remediation of hydrocarbon pollutants and energy sustainability. Traditional approaches focus on oxygen-activating oxides as support which provides the oxygen activation at the catalyst-support peripheral interface. Here we report a new approach to oxidation catalysts for total oxidation of hydrocarbons (e.g., propane) by surface oxygenation of platinum (Pt)-alloyed multicomponent nanoparticles (e.g., platinum-nickel cobalt (Pt–NiCo)). The in-situ/operando time-resolved studies, including high-energy synchrotron X-ray diffraction and diffuse reflectance infrared Fourier transform spectroscopy, demonstrate the formation of oxygenated Pt–NiOCoO surface layer and disordered ternary alloy core. The results reveal largely-irregular oscillatory kinetics associated with the dynamic lattice expansion/shrinking, ordering/disordering, and formation of surface-oxygenated sites and intermediates. The catalytic synergy is responsible for reduction of the oxidation temperature by ~100 °C and the high stability under 800 °C hydrothermal aging in comparison with Pt, and may represent a paradigm shift in the design of self-supported catalysts.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS2021

Melt Pool Imaging using a Configurable Architecture Additive Testbed System

This paper describes the inline (coaxial to laser) near infrared (NIR) camera sensor on the Configurable Architecture Additive Testbed (CAAT). The CAAT is an instrument that provides the capability to investigate laser based additive manufacturing (AM) processes and is configured for the metal powder bed fusion process. A low cost NIR camera is radiometrically calibrated to obtain coaxial, inline, imagery of laser generated melt pools. The camera capabilities, system optical path, and the uncertainty in the temperature measurement from NIR surface area scans on a bare titanium alloy plate are presented and discussed. The surface radiance measurements are compared to optical microscopy images of the melt pool width and depth. A metallic additive manufacturing process thermal model is developed in order to predict thermal distributions during laser scanning. The predicted thermal distributions by the model for different configurations are compared to the coaxial NIR measurements and discussed.

Additive manufacturing↗
NASA NTRS2013

Method for Reduction of Silver Biocide Plating on Metal Surfaces

Silver ions in aqueous solutions (0.05 to 1 ppm) are used for microbial control in water systems. The silver ions remain in solution when stored in plastic containers, but the concentration rapidly decreases to non-biocidal levels when stored in metal containers. The silver deposits onto the surface and is reduced to non-biocidal silver metal when it contacts less noble metal surfaces, including stainless steel, titanium, and nickel-based alloys. Five methods of treatment of contact metal surfaces to deter silver deposition and reduction are proposed: (1) High-temperature oxidation of the metal surface; (2) High-concentration silver solution pre-treatment; (3) Silver plating; (4) Teflon coat by vapor deposition (titanium only); and (5) A combination of methods (1) and (2), which proved to be the best method for the nickel-based alloy application. The mechanism associated with surface treatments (1), (2), and (5) is thought to be the development of a less active oxide layer that deters ionic silver deposition. Mechanism (3) is an attempt to develop an equilibrium ionic silver concentration via dissolution of metallic silver. Mechanism (4) provides a non-reactive barrier to deter ionic silver plating. Development testing has shown that ionic silver in aqueous solution was maintained at essentially the same level of addition (0.4 ppm) for up to 15 months with method (5) (a combination of methods (1) and (2)), before the test was discontinued for nickel-based alloys. Method (1) resulted in the maintenance of a biocidal level (approximately 0.05 ppm) for up to 10 months before that test was discontinued for nickel-based alloys. Methods (1) and (2) used separately were able to maintain ionic silver in aqueous solution at essentially the same level of addition (0.4 ppm) for up to 10 months before the test was discontinued for stainless steel alloys. Method (3) was only utilized for titanium alloys, and was successful at maintaining ionic silver in aqueous solution at essentially the same level of addition (0.4 ppm) for up to 10 months before the test was discontinued for simple flat geometries, but not for geometries that are difficult to Teflon coat.

Steele, John↗
NASA NTRS1988

Effect of melt spinning on grain size and texture in Ni-Mo alloys

Chill-block melt-spun ribbons of Ni-Mo alloys with Mo contents of 8 to 41.8 wt pct have been examined for microstructure and texture dependence on processing conditions. Linear features observed in grains solidified with a planar liquid-solid interface at the quench side of the ribbons have been identified to be due to the twins on the (111)gamma plane formed during solidification. Grain size variation with the wheel surface speed and the alloy composition has been studied. The crystallographic texture on the quench side and the free surface side of the ribbons has been investigated.

Tewari, S. N.↗
NASA NTRS1976

Refinement of Promising Coating Compositions for Directionally Cast Eutectics

The successful application of high creep strength, directionally solidified gamma/gamma prime-delta (Ni-19.7Cb-6Cr-2.5Al) eutectic superalloy turbine blades requires the development of suitable coatings for airfoil, root and internal blade surfaces. In order to improve coatings for the gamma/gamma prime-delta alloy, the current investigation had the goals of (1) refining promising coating compositions for directionally solidified eutectics, (2) evaluating the effects of coating/ substrate interactions on the mechanical properties of the alloy, and (3) evaluating diffusion aluminide coatings for internal surfaces. Burner rig cyclic oxidation, furnace cyclic hot corrosion, ductility, and thermal fatigue tests indicated that NiCrAlY+Pt(63 to 127 micron Ni-18Cr-12Al-0.3Y + 6 micron Pt) and NiCrAlY(63 to 127 micron Ni-18Cr-12Al-0.3Y) coatings are capable of protecting high temperature gas path surfaces of eutectic alloy airfoils. Burner rig (Mach 0.37) testing indicated that the useful coating life of the 127 micron thick coatings exceeded 1000 hours at 1366 K (2000 deg F). Isothermal fatigue and furnance hot corrosion tests indicated that 63 micron NiCrAlY, NiCrAlY + Pt and platinum modified diffusion aluminide (Pt + Al) coating systems are capable of protecting the relatively cooler surfaces of the blade root. Finally, a gas phase coating process was evaluated for diffusion aluminizing internal surfaces and cooling holes of air-cooled gamma/gamma prime-delta turbine blades.

Strangman, T. E.↗
DOE OSTI2021

CO and H 2 adsorption on Au-Ni bimetallic surfaces: a combined experimental and DFT theoretical study

Au-Ni bimetallic thin films were grown on refractory metal substrates. CO and H 2 adsorption on Au-Ni bimetallic surfaces have been studied by a combination of in situ polarization modulation infrared reflection absorption spectroscopy (PM-IRRAS), temperature-programmed desorption (TPD), and density functional theory (DFT) calculations. It is found CO desorption peak shifts from 413 K on pure Ni surfaces to 293 K on the isolated Ni atoms formed by alloying with Au atoms. The sharp decrease of CO desorption temperature on Au-Ni surfaces with increasing Au coverage is caused by the change of the favored CO adsorption sites from bridge/hollow sites on pure Ni surfaces to Ni top sites on Au-Ni bimetallic surfaces. In situ PM-IRRAS shows two CO adsorption bands on Au sites at 2119 cm −1 and 2103 cm −1 on Au-Ni surfaces at 80 K, which are due to CO bound on under-coordinated Au atoms and electron negatively charged Au sites modified with nearby Ni atoms, respectively. Even with the Au-Ni surface temperature at as low as 100 K, CO adsorption induced Ni surface segregation has been observed by in situ PM-IRRAS. Furthermore, DFT calculation results discover the adsorption energy of CO on Ni top sites continues to decrease with increasing Au coverage due to the geometric ensemble effect and the lowered d-band center after Ni alloying with Au. H 2 desorption temperature decreases from 363 K on pure Ni thin films to 302 K with increasing Au coverage to 0.6 ML. A new H 2 peak appears at around 170 K on the Au-Ni surfaces with Au coverages between 0.6 ML and 0.9 ML. This new H 2 TPD peak is assigned to H 2 desorption from the totally isolated Ni sites. With Au coverage above 1.5 ML, there is no any H 2 desorption detected. Finally, the combined surface science studies and DFT calculations provide new insights into the surface structure-activity correlation of Ni-base bimetallic surface alloys.

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

PdCu Alloy Catalyst for Inhibition‐free, Low‐temperature CO Oxidation

Designing robust catalysts for low‐temperature oxidation is pertinent to the development of advanced combustion engines to meet increasingly stringent emissions limitations. Oxidation of CO, hydrocarbon, and NO pollutants over platinum‐group catalysts suffer from strong inhibition due to their competitive adsorption, while coinage metals are generally slow at activating O 2 . Through computational screening, we discovered a PdCu alloy catalyst that completely oxidizes CO below 150 °C without inhibition by NO, propylene or water. This is attributed primarily to geometric effects and the presence of CO bound to Pd sites within the Cu‐rich surface of the PdCu alloy. Here, we demonstrate that the novel PdCu catalyst can be used in tandem with a PtPd catalyst to achieve sequential, inhibition‐free, complete oxidation of CO in a two‐bed system, while also achieving 50 % NO conversion below 120 °C. Moreover, neither water nor propylene adversely affect the low temperature CO oxidation activity.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗