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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 451 records · Page 25
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

In-situ investigation of incipient melting in a 319 type Al alloy using laser scanning confocal microscopy

Highlights: • In-situ analysis of incipient melting of ternary eutectic in Al alloy. • Incipient melting occurred in three distinct stages in the eutectic. • Increased heating rate increase rate of liquid film propagation. • Incipient melting transformed initial eutectic structure and caused oxidation. • Study determined incipient melting mechanism for eutectic structures. - Abstract: The modified 319 Al alloy system has been used extensively in precision sand casting of automotive powertrain applications such as engine blocks and cylinder heads, with significant improvement in vehicle fuel efficiency. However, a concern in elevated temperature processing of Al alloys, such as heat treatment and hot working processes, is incipient melting of secondary phases, which is deleterious to mechanical properties. In this study, the laser scanning confocal microscopy (LSCM) technique was used in the analysis of in-situ changes in microstructure as a result of incipient melting. Microstructural analysis was carried out prior to and following elevated temperature exposure in the LSCM using optical microscopy, SEM and EDX. The results suggest that incipient melting of the Al-Al{sub 2}Cu-Al{sub 5}Mg{sub 8}Cu{sub 2}Si{sub 6} ternary eutectic clusters was initiated by the formation of a liquid film which propagated rapidly from the eutectic clusters, coating the Al dendrites in regions adjacent to the eutectic clusters. Following film formation, the ternary eutectic clusters melted completely. Incipient melting also resulted in a localized change in composition in the interdendritic channels as supported by a change in cluster morphology from eutectic to a combination of coarse blocky Al-Cu-Ni and Si particles, and ultra-fine eutectic.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Evolution of Fe-Rich Intermetallics in Al-Si-Cu 319 Cast Alloy with Various Fe, Mo, and Mn Contents

In the present work, the precipitation and preferential selection of Fe-rich intermetallics in Al-Si-Cu 319 cast alloys with two Fe contents (0.3 and 0.7 wt pct) and various Mo contents (0 to 0.4 wt pct) were investigated. The results showed that two types of platelet β-Fe (defined as eutectic β-Fe and pre-eutectic β-Fe) and α-Fe can precipitate depending on the alloy compositions, such as the Fe and Mo contents. Generally, the addition of Mo promotes the formation of α-Fe instead of β-Fe. However, its effect on the phase competition between β-Fe and α-Fe is greatly related to the Fe content. In alloys with low Fe content (0.3 pct), an addition of 0.37 pct Mo can promote the complete precipitation of α-Fe and suppress the formation of eutectic β-Fe. However, in alloys with high Fe content (0.7 pct), only the pre-eutectic β-Fe amount decreases with increasing Mo addition, leaving the eutectic β-Fe almost unchanged, while both pre-eutectic β-Fe and eutectic β-Fe can be fully suppressed with a combined addition of Mn (0.24 pct) and Mo (0.4 pct). Compared with Mn, Mo exhibits a stronger effect on the promotion of α-Fe. The combined addition of Mn and Mo can achieve better modifications of both pre-eutectic and eutectic β-Fe in 319 alloys with high Fe content.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Melting and thermal expansion in the Fe-FeO system at high pressure

Melting in the Fe–FeO system was investigated at pressures up to 93 GPa using synchrotron X-ray diffraction (XRD) and a laser heated diamond anvil cell (DAC). The criteria for melting were the disappearance of reflections associated with one of the end-member phases upon raising the temperature above the eutectic and the reappearance of those reflections on dropping the temperature below the eutectic. The Fe–FeO system is a simple eutectic at 50 GPa and remains eutectic to at least 93 GPa. The eutectic temperature was bound at several pressure points between 19 and 93 GPa, and in some cases the liquidus temperature was also determined. The eutectic temperature rises rapidly with pressure closely following the melting curve of pure Fe. A detailed phase diagram at 50 GPa is presented; the eutectic temperature is 2500 ± 150 K and the eutectic composition is bound between 7.6 ± 1.0 and 9.5 ± 1.0 wt.% O. The coefficient of thermal expansion of FeO is a strong function of volume and decreases with pressure according to a simple power law.

Seagle, C. T.↗
DOE OSTI2023

Transmission electron microscopy of the rapid solidification microstructure evolution and solidification interface velocity determination in hypereutectic Al-20at.%Cu after laser melting

The evolution of rapid solidification (RS) microstructure and solidification interface velocity has been studied experimentally by in-situ transmission electron microscopy and postmortem characterization for hypereutectic Al-20at.%Cu (37 wt.%Cu) after laser melting. Four morphologically distinct regions formed via growth modes changing from θ-Al 2 Cu phase dendrites to eutectic cell growth, possibly α-Al dendrite growth (α-cell), banded growth, and α-Al plane front growth. Tendency for faceting and low capacity for solute trapping limited the θ-phase dendrite growth to solidification interface velocity v < 0.07 m/s. Consequently, formation of pro-eutectic micro-constituent was suppressed, and RS microstructure formation was dominated by eutectic, α-cell, and banded morphology grains for the Al-20at.%Cu alloy. Eutectic growth operated for interface velocity of 0.1 m/s ≤ v < 0.3 m/s, with a transition from regular lamellar, 2-λ and 1-λ mode to a dense irregular morphology dominated by α-phase at v = 0.3 m/s. Interface temperature calculations indicated feasibility of α-cell growth mode for 0.3 m/s ≤ v < 0.7 m/s. Banded growth occurred for 0.7 m/s ≤ v < 1.3 m/s. Plane front α-phase growth was evident for interface velocities v ≥ 1.3 m/s. Previous work on rapid solidification microstructure development in hypereutectic Al-Cu alloys reported a regime of α-cell growth subsequently to eutectic and prior to transition to banded growth for Al-19at.%Cu (36 wt.%Cu), while for Al-22at.%Cu (40 wt.%Cu) eutectic growth transitioned directly to α-plane front growth without emergence of a banded regime. Finally, based on the current study the disappearance of the banded growth regime occurs for a composition larger than 20at.%Cu.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Microstructure and mechanical properties of hypoeutectic Al–6Ce–3Ni-0.7Fe (wt.%) alloy

Here, a hypoeutectic, Fe-modified Al–Ce–Ni alloy (Al–6Ce–3Ni-0.7Fe, wt.%) is studied in terms of microstructure, thermal stability, ambient temperature strengthening, and creep resistance. The as-cast microstructure consists of primary Al dendrites and interdendritic binary eutectic regions (Al–Al11Ce3 and/or Al–Al9(Fe,Ni)2), with micron/submicron lamellar spacing, depending on the location along the height of the ingot. The cast alloy exhibits excellent coarsening resistance at 400 °C, with mostly unchanged microstructure and microhardness after 6 weeks of aging, indicating good thermal stability of Al11Ce3 and Al9(Fe,Ni)2. Orowan strengthening and load transfer are identified as strengthening mechanisms at ambient and elevated temperature. A high volume fraction of the intermetallic phases (providing load transfer) and relatively coarse eutectic spacing (for modest Orowan strengthening) result in a moderate as-cast microhardness of 566 ± 32 MPa. Creep resistance at 300 and 350 °C is similar to a binary Al-12.5Ce eutectic alloy (with twice the Ce content) because of two countering effects: Al–6Ce–3Ni-0.7Fe shows a higher volume fraction of strengthening intermetallic phases, but it also exhibits a large fraction of primary Al dendrites which weaken the alloy. By contrast, the alloy, when laser-remelted at the surface, has a fully eutectic microstructure without primary aluminum dendrites achieved by high undercooling on solidification, with a refined network of eutectic phases that doubles the microhardness as compared to the cast alloy. Whereas coarsening is faster due to the shorter diffusion distances between the eutectic phases, hardness remains ~30% higher than the as-cast alloy after ~6 weeks aging at 400 °C.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Coordination and thermophysical properties of select trivalent lanthanides in LiCl–KCl

The coordination chemistry of various fission and decay products, such as actinides and lanthanides, are crucial to the commercial deployment of molten salt reactors as they can affect the thermophysical properties. In this report we examined the structure, coordination environment, and physical properties such as the density and the vibrational density of states for three lanthanide species, namely Ce, Eu, and Sm in the LiCl–KCl eutectic system using a combination of quantum mechanics simulations and spectroscopic experiments. Quantum mechanics molecular dynamics (QM-MD) modelling was employed to determine the physical properties of each system resulting in accurate local coordination of each species. Then, the vibrational density of states (DOS) was determined using a two-phase thermodynamic modelling which was then compared to the experimentally obtained Raman spectra of the species in molten LiCl–KCl having the eutectic composition. We find that Ce 3+ , Eu 3+ and Sm 3+ all adopt octahedral local coordination environments in the eutectic salt composition in good agreement with experimental results. Ce3+ is found to fluctuate between an octahedral six-coordinated and a seven-coordinated structure due to the increased local proximity of Cl in the eutectic salt, resulting in a lower fluidicity/diffusivity than the other trivalent lanthanides studied. The thermophysical properties of the eutectic composition with trivalent lanthanides were not significantly different from the pure eutectic salt composition, but several changes were noted.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2016

Metal Fuel Implications on Severe Accident Scenarios

Superior steady-state irradiation performance of metal fuel has been demonstrated, and metal fuel has been the choice for recent sodium-cooled fast reactor designs, e.g. PRISM, SAFR, 4S, TWR, PGSFR, and so on. Metal fuel also has excellent transient capabilities. The metal fuel itself does not impose any restrictions on transient operations or load-following capabilities. Metal fuel has benign run beyond cladding breach (RBCB) performance characteristics. Because metal fuel is compatible with sodium, there is no reaction product and the fuel loss is practically zero. Metal fuel is expected to be very reliable. However, even if unforeseen fuel pin failure occurs, it will simply release gases and does not cause failure propagation to neighboring pins. The eutectic formation temperature between the fuel and the cladding has been considered a critical parameter for the metal fuel pin design. The onset of fuel-cladding eutectic formation starts in the 700-725 deg. C temperature range, depending on the fuel alloy and cladding types. However, at this onset temperature, not much interaction occurs. In fact, even at 100 deg. C above the eutectic temperature, the eutectic penetration into the cladding is minimal in one hour. Only at much higher temperatures, close to the fuel melting point itself, the eutectic penetration into cladding becomes rapid. Therefore, the eutectic formation is not a primary safety concern during transient overpower conditions. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2024

Significantly Promoting the Thermal Conductivity and Machinability of Negative Thermal Expansion Alloy via In Situ Precipitation of Copper Networks

Rapid advancements in electronic devices yield an urgent demand for high-performance electronic packaging materials with high thermal conductivity, low thermal expansion, and great mechanical properties. However, it is a great challenge for current design philosophies to fulfill all the requirements simultaneously. Here, an effective strategy is proposed for significantly promoting the thermal conductivity and machinability of negative thermal expansion alloy (Zr,Nb)Fe 2 through eutectic precipitation of copper networks. The eutectic dual-phase alloy exhibits an isotropic chips-matched thermal expansion coefficient and a thermal conductivity enhancement exceeding 200% compared with (Zr,Nb)Fe 2 , along with an ultimate compressive strength of 550 MPa. The addition of copper reorganizes the composition of (Zr,Nb)Fe 2 , which smooths the magnetic transition and shifts it toward higher temperature, resulting in linear low thermal expansion in a wide temperature range. The highly fine eutectic copper lamellae construct high thermal conductivity networks within (Zr,Nb)Fe 2 , serving as highways for heat transfer electrons and phonons. The in situ forming of eutectic copper lamellae also facilitates the mechanical properties by enhancing interfacial bonding and bearing additional stress after yielding of (Zr,Nb)Fe 2 . This work provides a novel strategy for promoting thermal conductivity and mechanical properties of negative thermal expansion alloys via eutectic precipitation of copper networks.

36 MATERIALS SCIENCE↗
DOE OSTI2018

The Binary Alkali Nitrate and Chloride Phase Diagrams: NaNO{sub 3}-KNO{sub 3}, LiNO{sub 3}-NaNO{sub 3}, LiNO{sub 3}-KNO{sub 3}, and NaCl-KCl

LiNO{sub 3}-NaNO{sub 3}, LiNO{sub 3}-KNO{sub 3,} NaNO{sub 3}-KNO{sub 3}, and NaCl-KCl phase relations were formulated using the regular solution model to obtain desired compositions for their potential application as a heat transfer fluid. The simultaneous nonlinear equations formed were solved numerically using a contour plot technique in Matlab. An algorithm was developed to determine the real roots of the coupled nonlinear equations and subsequent phase diagrams were constructed. The phase diagrams were compared with those predicted using FactSage thermochemical package and literature data from experimental studies. The calculated NaNO{sub 3}-KNO{sub 3} phase diagram shows that this system has a eutectic point at 0.5 mole fraction of KNO{sub 3} with a eutectic temperature of 220.85 °C, while the LiNO{sub 3}-KNO{sub 3} system was found to have a eutectic point at 0.44 mole fraction LiNO{sub 3} at 137 °C. The LiNO{sub 3}-NaNO{sub 3} system shows a eutectic at 0.524 mole fraction LiNO{sub 3} at 192.8 °C, and finally the NaCl-KCl system has a eutectic point at 0.48 mole fraction NaCl at 634 °C. The liquidus and solidus curves obtained fitted close against values obtained from the quasi-chemical model used in FactSage and experimental values from the literature. This study showed that the regular solution model combined with the contour plots approach can sufficiently describe the liquidus–solidus curves of the alkali binary nitrate and chloride systems and could be a useful method for predicting the phase diagrams for higher order alkali nitrates and chlorides.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Influence of the Composition on the Solidification Path, Microstructure Evolution and Mechanical Properties of Al-Cu-Mg Alloys

The influence of the initial composition on the solidification path, microstructure evolution, thermophysical properties and mechanical properties of Al-Cu-Mg alloys was investigated. The solidification paths of the investigated alloys were determined by analyzing the solidification structure, and then the experimentally determined paths were compared with those from the calculated results. Three of the investigated alloys experienced typical ternary eutectic solidification, and the other four alloys experienced quasiperitectic reactions. Due to differences in the initial compositions, different eutectic morphologies were formed during the solidification process. The binary eutectic phases, (α-Al + Al{sub 2}Cu) and (α-Al + Al{sub 6}CuMg{sub 4}), and the (α-Al + Al{sub 6}CuMg{sub 4} + Al{sub 8}Mg{sub 5}) ternary eutectic phase tended to exhibit divorced growth, and the (α-Al + Al{sub 2}CuMg), (α-Al + Al{sub 6}CuMg{sub 4}) and (α-Al + Al{sub 2}Cu + Al{sub 2}CuMg) eutectic phases tended to exhibit coupled growth. The results indicated that the initial composition, solidification path, microstructure and morphology could greatly affect the melting enthalpy, microhardness and compressive strength of the investigated Al-Cu-Mg alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Deformation Behavior of Pure Copper Castings with As-Cast Surfaces for Electrical Parts

Herein, the tensile deformation behavior of pure copper castings with as-cast surfaces was investigated. It was found that small and sufficiently large uniform elongation types corresponded, respectively, to the presence or absence of a Cu-Cu{sub 2}O eutectic phase in the microstructure. Fissure defects were observed near the as-cast surfaces when the eutectic phase was present, probably leading to stress concentration. On the other hand, surface pinholes were observed when the eutectic phase was absent, and these were not prevented by directional solidification. Although the as-cast specimens (non-directionally solidified) exhibited a slightly reduced uniform elongation compared to the machined specimens in the absence of the eutectic phase, the directionally solidified as-cast samples exhibited a uniform elongation that was similar to that of the machined specimens. In addition, micropore arrays were formed along the grain boundaries inside the castings when the eutectic phase was absent, whereas almost no micropores were observed inside the directionally solidified as-cast specimens because the solidification process involved a faster cooling rate and/or higher temperature gradient. These results do not only suggest the existence of surface pinholes but also indicate that microporosity can reduce the cross-sectional area of the specimens, thus, affecting their uniform elongation.

36 MATERIALS SCIENCE↗
DOE OSTI2017

The microstructure and composition of equilibrium phases formed in hypoeutectic Te-In alloy during solidification

As a key tellurium atoms evaporation source for ultraviolet detection photocathode, the hypoeutectic Te{sub 75}In{sub 25} alloy was prepared by employing a slow solidification speed of about 10{sup −2} K/s. The microstructure and chemical composition of the equilibrium phases formed in the as-prepared alloy were studied in this research work. The experimental results show that the as-prepared Te-In alloy was constituted by primary In{sub 2}Te{sub 5} phase and eutectic In{sub 2}Te{sub 5}/Te phases. The eutectic In{sub 2}Te{sub 5}/Te phases are distributed in the grain boundaries of primary In{sub 2}Te{sub 5} phase. With the slow solidification speed, a pure eutectic Te phase without any excessive indium solute was obtained, where Te content of eutectic Te phase is 100 mass%. Moreover, it can be considered that the stress between the In{sub 2}Te{sub 5} and Te phases plays an important role in reducing the tellurium vapor pressure in Te{sub 75}In{sub 25} alloy. - Highlights: • The microstructure of Te-In alloy as an evaporation source was analyzed. • A pure eutectic Te phase was obtained by using a slow solidification speed method. • The relation between vapor pressure and inner-stress in the alloy was discussed.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Effects of boron addition on the morphology of silicon phases in Al-Si casting alloys

Highlights: • The influence of boron on Si phase was studied. • Boron addition reduces the length of eutectic Si plates in Al-11Si alloys. • Boron addition promotes the nucleation temperature of primary Si phases in Al-14Si alloys. • Boron addition increases the twin density in the <112>{sub Si} growth direction of eutectic Si in Al-11Si and Al-14Si alloys. - Abstract: The influence of B elements on the morphology of Si phases in Al-11Si and Al-14Si alloys has been investigated employing Optical Microscope, Scanning Electron Microscopy, Transmission Electron Microscopy and Differential Scanning Calorimetry. In Al-11Si alloy, the addition of B element not only refines the primary Al dendrites, but also reduces the length of eutectic Si plates. In Al-14Si alloys, the addition of B element promotes the nucleation temperature of primary Si phases, but shows weak influence on the nucleation temperature of eutectics. The effects of B element on the morphologies of both primary Si particle and eutectics can be attributed to the interaction between B and Si elements during the solidification process.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Interdiffusion Behavior of U{sub 3}Si{sub 2} and FeCrAl via Diffusion Couple Studies

Uranium Silicide (U{sub 3}Si{sub 2}) is in use as a dispersion plate fuel in test reactors, but has not been fully tested in light water reactor (LWR) conditions. U{sub 3}Si{sub 2} pellets have been fabricated for use in commercial LWRs as part of an accident tolerant fuel system U{sub 3}Si{sub 2} has a higher uranium loading density as well as a higher thermal conductivity relative to UO{sub 2}. FeCrAl alloy is a candidate cladding material to replace the industry standard, Zircaloy. FeCrAl has outstanding high-temperature mechanical strength and oxidation resistance under accident conditions. The U{sub 3}Si{sub 2}-FeCrAl system is expected to provide more than double the amount of time from a Scram until failure criteria for the reactor is met, as well as producing roughly half the amount of H{sub 2} in the event of a loss of coolant accident (LOCA). Uranium and iron have well know eutectics that may affect/enhance diffusion of the U{sub 3}Si{sub 2}/FeCrAl fuel system. The interaction of iron with molten uranium has been investigated In the U-Fe system, UFe{sub 2}, which melts congruently at 1235 deg. C, forms a eutectic with iron that melts at 1080 deg. C and has a composition of U-77at% Fe. UFe{sub 2} also forms a eutectic with uranium that melts at 725 deg. C and has a composition of U-34at% Fe. The U-34at% Fe eutectic extended the temperature range down to 740 deg. C. Regular operating temperatures for U{sub 3}Si{sub 2} fuel is expected to be around 300 - 400 deg. C. The eutectics of iron and uranium would nominally only be of concern in accident scenarios.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Microstructure and strengthening of Al-6Ce-3Ni-0.7Fe (wt%) alloy manufactured by laser powder-bed fusion

In this study, an Al-6Ce-3Ni-0.7Fe (wt%) alloy was fabricated via laser powder-bed fusion and its microstructure, thermal stability, tensile properties, and creep properties are investigated for two rapid-solidification rates with different eutectic spacings. For both faster- and slower-cooled states, the as-fabricated alloy mostly shows elongated grains with very fine eutectic networks (~40 nm lamellar width) comprising a high-volume fraction (~18 %) of intermetallic phases. Faster-cooled samples, however, display a less continuous eutectic network with finer spacing (~100 nm), leading to higher Orowan strengthening and therefore superior microhardness and yield stress up to ~350 °C. Upon aging (300 - 450 °C), micron-size Al 9 (Ni,Fe) 2 needle-like precipitates form within grains, and the Al 11 Ce 3 eutectic network spheroidizes, while retaining a submicron width and spacing, resulting in 33–37 % drop in microhardness after 144 h aging at 400 °C. Limited tensile ductility (~6 %) and creep ductility (~1-2 %) are measured for both faster- and slower-cooled alloys due to an inhomogeneous microstructure, where cavitation preferentially initiates at melt-pool boundaries, precipitate-free zones, and/or denuded zones, eventually leading to local fracture. Denuded zones, induced by stress, form due to diffusional flow with stress-dependent orientations, and are identified as microstructurally weak regions leading to strain localization. The present alloy does not show a significant difference in 300 °C creep resistance between: (i) tensile and compressive loading, (ii) faster- and slower-cooled samples, and (iii) continuous and spheroidized eutectics. Creep resistance at 300 °C is comparable to that of a Ce-richer Al-10.5Ce-3.1Ni-1.2Mn (wt%) alloy, despite the formation of denuded zones and needle-like Al 9 (Ni,Fe) 2 precipitates.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Determination of a surrogate for plutonium electrorefining

Conducting research experiments on plutonium electrorefining is difficult due to the significant hazards and regulations associated with nuclear materials. Finding a surrogate for plutonium electrorefining studies would enable more fundamental research to be conducted. Potential surrogates were first identified by determining the physical properties required to conduct electrorefining at the same conditions commonly used in plutonium electrorefining, a molten metal and molten CaCl 2 at 1123 K. Ce-CeCl 3 , In-InCl 3 , and Pb-PbCl 2 were the only potential surrogates identified using these constraints. Sn-SnCl 2 was also tested at these same conditions. More potential surrogates were identified by changing the matrix salt and operating temperature. This expanded the potential surrogate list to also include Zn-ZnCl 2 , Sn-SnCl 2 , and Bi-BiCl 3 . Zn-ZnCl 2 was used with the LiCl-CaCl 2 (65:35 mol%) eutectic at 773 K. Sn-SnCl2 and Bi-BiCl 3 were used with the LiCl-KCl-CaCl 2 (50.5:44.2:5.3 mol%) eutectic at 673–773 K. Ce electrorefining in molten CaCl 2 resulted in a difficult to separate colloid mixture of Ce, Ca and Cl. Electrorefining rates for In in molten CaCl 2 were too slow due to InCl 3 volatilizing out of the molten salt. Only trace amounts of SnCl 2 was retained in the CaCl 2 at 1123 K resulting in impractical electrorefining rates. Zn metal product was successfully collected in the LiCl-CaCl 2 eutectic molten salt, but the metal obtained did not coalesce into one piece. Sn and Bi were successfully electrorefined in the LiCl-KCl-CaCl 2 eutectic molten salt and coalesced into product rings with high yields and coulombic efficiencies. Finally, while a surrogate could not be identified using the same conditions as plutonium electrorefining, two possible surrogates, Sn-SnCl 2 and Bi-BiCl 3 , were found that could imitate the physical configuration (i.e., molten salt on top of molten metal) of plutonium electrorefining at a reduced temperature using the eutectic LiCl-KCl-CaCl 2 salt at 673–773 K in place of CaCl 2 at 1123 K.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Analysis and Thermal Property Investigations into Ternary Actinide Chloride Salt Systems Containing UCl3 and PuCl3

While regulators, the scientific community, and MSR developers still lack access to literature data on the thermal properties of clean fuel salts, even less information is available on the properties of fuel salts containing impurities. It is essential to understand, benchmark, and predict crucial data on the changes in thermal properties of fuel salt systems due to impurities arising from moisture, corrosion, and reactor operation (i.e., fission products). This research focuses on two actinide fuel salts (1) to investigate a worst-case scenario buildup of actinide fission product in a NaCl-UCl3 eutectic fuel salt and (2) to investigate NaCl-PuCl3 eutectic salt after 1000 hours of operation in a natural circulation flow loop flow to determine if corrosion or atmospheric (moisture/oxygen) products are present. For the first salt, a conservative assumption or worst-case scenario, for fission product buildup in a fuel salt was investigated by adding PuCl3 to eutectic 67 mol% NaCl – 33 mol% UCl3 salt resulting in a ternary salt having a composition of 61 mol% NaCl – 30 mol% UCl3 – 9mol% PuCl3. Addition of PuCl3 to eutectic NaCl-UCl3 resulted in a ternary salt that had a higher melting temperature than either the NaCl-PuCl3 or NaCl-UCl3 binary eutectic mixture. Addition of PuCl3 also resulted in an increase in density which was expected. The second salt was extracted from a micro loop. The composition of the fuel (primary) salt prior to flow loop operations was determined to be 64 mol% NaCl – 36 mol% PuCl3, however, the post-flow loop salt showed increased levels of MgCl2 and NaCl changing the salt composition to 10 mol% MgCl2 – 63mol% NaCl – 26mol% PuCl3) indicating the primary salt interacted with the rinse salt. Analysis of the post flow loop salt detected low concentrations of Al, Ni, Co, Nb, and Zr, most likely corrosion products from the flow loop material of construction. Contamination of the fuel salt (with the rinse salt NaCl-MgCl2) decreased the density by approximately 10% and reduced the onset of melting temperature by 50 °C, from 451 °C to approximately 400 °C. Results from the fission product simulated salt (61 mol% NaCl – 30 mol% UCl3 – 9mol% PuCl3) and the corrosion product salt (10 mol% MgCl2 – 63mol% NaCl – 26mol% PuCl3) will be included in two separate manuscripts for submission to peer-reviewed journals.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

Size Distribution of Graphite Nodules in Hypereutectic Cast Irons of Varying Nodularity

An SGI was machined into 400 g cylindrical pieces and remelted in an electrical resistance furnace protected by Ar gas to produce materials ranging from SGI to CGI. The graphite morphology was controlled by varying the holding time at 1723 K (1450 °C) between 10 and 60 minutes. The discrete sectional size distribution of nodules by number density was measured on cross sections of the specimens and translated to volumetric distribution by volume fraction. Subpopulations of nodules were distinguished by fitting Gaussian distribution functions to the measured distribution. Primary and eutectic graphite, were found to account for most of the volume of nodular graphite in all cases. For holding times of 40 minutes and greater, corresponding to nodularity roughly below 40 pct, the primary subpopulation was very small and difficult to distinguish, leaving eutectic nodules as the dominant subpopulation. The mode and standard deviation of the two subpopulations were roughly independent of nodularity. Moreover, the nodular and vermicular graphite were segregated in the microstructure. In conclusion, the results suggest that the parallel development of the vermicular eutectic had small influence on the size distribution of eutectic graphite nodules.

36 MATERIALS SCIENCE↗