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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 523 records · Page 29
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

The Effect of Aging on the Delamination Fracture Energy of Glass Solar Reflectors

Thin metal and metal oxide films deposited on glass or polymer substrates have been widely applied to manufacture front surfaced solar reflectors such as those used in the concentrated solar power (CSP) systems due to the facts that they are highly transparent, resistant to ultraviolet (UV) light and abrasion, and chemically inert. However, the reliable operation over long periods of outdoor exposure of such solar reflectors depends on the adequate adhesion between each layer to prevent delamination and subsequent failure. We report results from measurements of the delamination fracture energy (DFE) of the weakest interface in both as-deposited and aged reflectors, where the reflector construction consists of a glass/copper/silver/oxide stack. In this study, DFE was measured using a width-tapered beam method and the test results showed that the weakest interface of this solar reflector is the copper-glass interface, with a delamination fracture energy of approximately 4.4 J/m 2 . In order to verify the test results, finite element (FE) simulations were run using the commercial software package ABAQUS 6.14 based on the cohesive zone model (CZM). In the simulations, the DFE derived from the delamination measurement was treated as an input and the delamination forces from the FE simulations were compared to the experimental results. The good agreement between the tested and simulated delamination force indicated that this width-tapered beam method is accurate even for very small DFE, making it appropriate to test the DFE of front surfaced glass solar reflectors. Additionally, in order to study the aging effect on the DFE, accelerated aging tests were conducted using samples with different protective coatings, one group of samples with alumina ( Al 2 O 3 ) protective coating and the other group with titania ( TiO 2 ) protective coating. The DFE after 50 and 100 hours of accelerated aging were measured. The test results showed that the copper-glass interface would still be the weakest interface for all samples after aging, and the DFE for samples with Al 2 O 3 protective coating was unchanged whereas the copper-glass interface was found to undergo statistically significant change after both 50 and 100 hours of aging for samples with TiO 2 protective coating. We found that DFE at the copper/glass interface decreased after 50 hours of aging then increased after 100 hours of aging. The origin of this non-monotonic response of TiO 2 coated reflectors under accelerated aging conditions is unknown.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Stereolithographic Fabrication of a Flow Cell For Improved Neurochemical Sensor Testing

The human brain remains a mystery to researchers. Scientists at Lawrence Livermore National Laboratory (LLNL) have developed highly sensitive and flexible multimodal multielectrode arrays (MEAs) with the potential to be both powerful diagnostic and therapeutic tools when dealing with neurological ailments such as Alzheimers, Parkinson’s, Post Traumatic Stress Disorder, and Traumatic Brain Injuries. These MEAs include biosensors in addition to electrodes for electrical stimulation and recording. The transition from the traditional rigid neural probes to the flexible MEAs has led LLNL researchers on the search for alternative testing and characterization methods for flexible devices in vitro. The rigid devices have been shown to be more abrasive and damaging to the brain when implanted, but due to their rigidity – are more robust and resilient to noise artifacts in in vitro testing. The flexible MEAs, similar in size and flexibility to a human hair, cause much less damage in the brain but have had a difficult time maintaining their integrity and collecting data without high-levels of noise due to the formation of inertial eddies (due to increased turbulent flow) moving the flexible MEA during in vitro testing. The goal of this project was to design a fluidic cell to allow for a more constant electrochemical testing & characterization of biosensors on these flexible MEAs. Design and fabrication of the fluidic cell was through the use of CAD software and a stereolithography printer using clear photopolymer resin (appropriate for biomedical use and quality resolution). Flow cells facilitate analyte delivery to biosensor surfaces in a more constant and controlled fashion, allowing for –in this case –a better electrodeposition of thin-film Platinum-Iridium (Pt-Ir) on MEAs of 16 Platinum disc electrodes 50µm in diameter. Platinum-Iridium alloy electrodes have been widely used in biomedical and industrial applications. Iridium adds mechanical stiffness to platinum. PtIr is a FDA approved electrode material for human implantable devices.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Slippery Omniphobic Covalently Attached Liquids for Extreme Anti-Scaling

Fouling is amajor unresolved problem in a varietyof industries including power generation, water desalination,and hydrometallurgy. In a heat exchanger, the accumulated salt scale could lead to a decrease in heat transfer, corrosion, blockage of flow and increasedpressure drop, resulting in higher operation costsand shortened equipment lifetime. The added operational costs due to active scale removal techniques such as mechanical abrasion and chemical inhibitors are responsible for 0.25% of the GDP in industrialized nations.Herewe utilize slippery omniphobic covalently attached liquids (SOCAL) dip coating on aluminum substrates to minimize surface energyand surface roughness, hence maximizingthe energy barrier for scale formation. To enable SOCAL surfacebinding on aluminum, we started by depositinga nanoscale(500 nm thick)adhesion layer of SiO2using scalable and cost-effective electrophoretic deposition (EPD), followed by SOCAL grafting to the SiO2.The EPD SiO2coating chemistry was tailored to achieve a smoothsurface finish which, combined with the low surface energyof the SOCAL coating, translated to extreme anti-scaling performance. Thermal degradation testing in an ambient environment revealed the covalently bonded SOCAL coatingswithstand temperatures of 100°C. To characterize scaling, we utilized CaSO4and CaCO3scale tests, showing up to 20X less scaling than uncoated aluminum. Descaling tests revealed that our SOCAL coatings dramatically decrease scale adhesion, resulting in rapid removal of scale buildup in highly supersaturated conditions. To investigate manufacturability, two alternate methods of SiO2deposition were tested, including physical vapor deposition and spin-on glass, with great success in coating smooth metallic substrates, but limited success due to the inability to coat arbitrarily shaped surfaces. Our work not only demonstrates a facile method of tailoring interfacial energy and roughness to control fouling, it develops cost-effective, scalable,and high performing anti-fouling coating applicable to aluminum surfacesfor a variety of applications.

Zhao, Hanyang↗
DOE OSTI2018

HIGH-STRENGTH LIGHTWEIGHT ENGINES FOR HEAVY-DUTY DIESEL TRUCKS

This project with Cummins supports the development of next generation heavy duty diesel engines that can achieve a 50% or better Break Thermal Efficiency (BTE). The fuel efficiency roadmap for the 50% BTE engine considers six main areas for efficiency improvement in the baseline engine, several of which involve making more efficient use of thermal energy (heat) in the engine. Increased operating temperatures and improved thermal management are expected to enable significant increases in $power$ $density$, thus resulting in greater power output for the same sized engine or engine downsizing (or light weighting) for the same power output. However, it has become apparent that several key components will be exposed to temperatures beyond the capabilities of current engine and exhaust materials, requiring the availability of the next generation of high temperature materials to allow the engine to reach the targeted efficiencies, commercially viable durability, and emission targets. The objective of this project was to identify and/or develop key materials, and evaluate their critical properties to enable the design and development of a lightweight, higher efficiency engine, with enhanced temperature capability and reduced heat-loss to the atmosphere in order to facilitate waste heat recovery and improved efficiency. An increase in the temperature capability of exhaust manifold materials, and piston materials were identified as having a positive influence on the efficiency of the next generation diesel engines. Since the current materials (High SiMo cast irons used in exhaust manifolds, and 4140 steel in pistons) are already operating near their limits of their temperature and strength capabilities, it was determined that new materials with the right combination of properties are required for these components. Oxidation and constrained thermal fatigue tests were used to down-select CF8C plus (CF8CP), a cast austenitic stainless steel, for exhaust manifolds capable of operating at higher temperatures. A prototype exhaust manifold was fabricated using CF8CP and successfully tested in a marine engine. A functionally graded multiple-layer thermal barrier coating system was designed with four layers of mixed bondcoat alloy (NiCoCrAlYHfSi) and yttria stabilized zirconia (YSZ) and was shown to reduce the effective thermal conductivity of the coating-substrate (steel and Ti-6Al-4V) system. The graded alloy and YSZ mixture were intended to achieve better match of thermal expansion coefficient (CTE) and minimize thermal stresses. Such coatings can increase the temperature capability of pistons fabricated from steel and Ti-alloys. Effect of oil additives and friction conformal contact friction tests showed there was a 15-30% reduction in friction by the polymer-graphite composite coating compared to the uncoated steel piston. Standalone Mn-P coating had little beneficial impact. Changing the oil from CJ-4 to PC-11 had little impact on the friction behavior in boundary lubrication. Wear behavior was tested under a point contact configuration with a high contact pressure. The candidate CK-4 oil showed similar or slightly better lubricity compared to the CJ-4 oil while the candidate FA-4 oil decisively increased the piston skirt wear. Although both coatings prevented scuffing failure observed for the uncoated steel skirt in a base oil without an additive package, they surprisingly caused a higher piston wear rate when tested in any of the fully formulated engine oil. The detrimental impact was attributed to the Mn-P film, either as a standalone coating, or a coating interlayer. The porous and brittle Mn-P film was broken during the wear test and the released hard Mn-P grains are suspected to cause third-body abrasion to accelerate the wear process. This work also evaluated the feasibility of developing an improved high temperature, low mass, cost-neutral turbocharger compressor wheel for heavy-duty engine applications from TiAl using additive manufacturing, utilizing its unique ability to fabricate high strength, low weight structures. This work has shown that the phase transforming nature of the TiAl alloys enable obtaining equiaxed microstructures in the as-built state without the need for tedious beam parameter manipulations. The HIPed structures have good RT tensile properties that will enable them to be surface machined to the required tolerance that can 2 then be heat treated to obtain the desired microstructures. Additionally, the negligible residual stresses stemming from the high build chamber temperatures ensure the parts are formed without cracks (one of the major issues in traditional manufacturing of these intermetallics).

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2019

Additive Manufacturing Fabrication of PEEK Counter-Current Centrifugal Contactor Components

Additive manufacturing (AM, also known as 3D printing) offers significant advantages for the fabrication of annular centrifugal contactor-separator (CCS) stages, particularly when complemented by post-processing via traditional machining. The shortcomings of 3D printing of CCSs are offset by its low cost, quick turnaround, and ability to manufacture enhanced mixing sections and multistage modules. High-density acrylic materials show promise for improved chemical resistance and mechanical properties. The demonstration of the MOEX process using acrylic AM CCS stages confirmed their full functionality and showed significant flexibility in geometry design while using relatively low-cost plastic materials. Over the past two years, AM has been used to produce low-cost centrifugal contactor components, ranging from bench-scale laboratory testing to a full-scale industrial process with on-hand availability of spare parts and great flexibility in design modifications and quick testing and implementation. However, the shortcomings of stereo lithography assembly (SLA)-printed acrylic components became apparent rather quickly. By the completion of the initial MOEX demonstration using the 9-stage 2-cm CCS bank, nearly half of the rotors had begun to fail from pitting and cracking. These problems were most likely caused by swelling of the rotor due to liquid absorption, resulting in improper excess run out, mechanical abrasion, and chemical exposure of the roughened surface. Additional deterioration of the acrylic stages was later discovered when the interiors of the acrylic housings began to experience flaking and delamination as the plastic dried out several weeks after the tests. All of these issues caused severe limitations to the lifespan of the CCS stages, which are acceptable for R&D but undesirable for commercial-scale production.

42 ENGINEERING↗
DOE OSTI2020

High Temperature Erosion In Particle Based CSP Systems

Particle based concentrated solar power plants are increasingly being considered as an alternative to molten salts. Although these particle based systems provide the inherent safety and enhanced lifetime from reduced corrosion compared to molten salt systems, they bring in complexities associated with surface erosion from falling particle impact and sliding motion along the surfaces. Past research on particle related erosion has been limited to high velocity applications and doesn’t necessarily coincide with the operating conditions in CSP systems. In our work, we evaluate characterize the rate of erosion for particles and containment materials at 800ºC. Three different types of erosion resulting from a) impact of solid particles on receiver, particle storage, and heat exchanger walls; b) abrasion erosion from particle sliding motion along walls; and c) attrition erosion as the particles breakdown from particle-to-particle contact and particle-to-wall interactions are evaluated and compared across a varied spectrum of particle and containment material spectrum. From the results, It is noted that temperature plays a key role in the rate of erosion experienced by any material. With the increase in temperature, materials become more ductile and are more readily sheared away from particle impinging or sliding motion. Furthermore, the particles themselves have higher susceptibility to breakdown which also lowers particle thermal absorptance and thus efficiency as heat transfer fluid.

14 SOLAR ENERGY↗
DOE OSTI2020

Report of the Condition of a General Electric Transportation Systems Gearbox

Wind power plant operations and maintenance (O&M) costs remain an appreciable contributor to the overall cost of wind energy. Premature of wind turbine gearboxes failures are often a result of abrasive wear, micropitting, scuffing, white-etch cracks, and macropitting issues. Micropitting is a fatigue phenomenon that occurs in Hertzian contacts in both gears and rolling-element bearings that operate in mixed or micro elastohydrodynamic lubrication regimes. Micropitting is influenced by and manifests itself in many different ways depending on operating conditions such as load, speed and operating temperature, and on factors such as gear geometry and accuracy, tooth flank roughness, percentage of tooth sliding, and lubricant composition. Despite much research by many investigators, micropitting remains complex, unpredictable, and difficult to control and remains a problem in wind turbine gearboxes. The purpose of this report is to document and describe the micropitting damage observed in a wind turbine gearbox, thereby facilitating further analysis and examination in future reports.

17 WIND ENERGY↗
DOE OSTI2020

High Temperature Erosion Modeling in Particle Based CSP Systems

1. Introduction. Wear and erosion damage of materials from solid particle and surface interactions is a major issue in various industries. Although more common in mining and oil and gas production, erosion is becoming a critical issue in renewable technologies as well such as particle based concentrated solar thermal power (CSP) systems. In particle based CSP systems, solid particles are used to absorb solar energy and as thermal storage. However, these particles may cause significant amount of wear to system components while through the system at high temperatures. This damage can be costly, and therefore, requires a greater understanding of solid particle erosion in CSP systems. Throughout the years, models and tools have been developed to predict and control erosion in industries such as oil and gas production. However, these erosion models and erosion prediction tools have been mainly developed based on erosion data for much higher velocities and lower temperatures, i.e. the operating conditions for which the existing models have been built are not pertinent to those expected in CSP system. It is known that erosion depends on many factors such as material properties, erodent particle properties, and particle impact speed and angle. However, the effect of temperature on erosion is not vastly investigated. In this work, a temperature-based correlation is introduced that will be used to modify the existing erosion models to predict erosion rates at velocities and temperatures relevant to Gen3 CSP systems. The existing models are first validated against erosion experiments run at low temperatures and low velocities. Subsequently, a temperature correction term is developed that can extend the existing models to high temperatures, based on the available experimental data showing the effect of temperature on impact erosion. 2. Erosion Models. Continuing sequence of impacts from solid particles on surfaces would result in loss of material due to mechanical interaction between solid surface and particles. Erosion equations have been developed to predict erosion under different conditions and erosion mechanism, including cutting and deformation erosion. These models are mainly either mechanistic, empirical, and semi-mechanistic models, when the latter combine the theory of the erosion mechanism and particle motion with the available experimental data. One of the first empirical correlation was introduced by American Petroleum Institute (API) Recommended Practice (RP) 14E [1]. This correlation was very conservative, and several improved empirical and semi-mechanistic equations were developed in the years following. More recently, the models introduced by Erosion/Corrosion Research Center (E/CRC) at the University of Tulsa and Arabnejad. et al. [2] are frequently used in the literature and industry, as they account for many parameters affecting erosion including particle impact speed and angle, material density and hardness, and particle size and shape. However, both these models were developed based on data at relatively high velocities and also do not take into account any mechanical changes in material associated with thermal cycling at high temperatures. 3. Erosion Prediction at High Temperatures. In this work, the accuracy of Arabnejad et al. model and E/CRC model is investigated to predict impact erosion at conditions relevant to Gen3 CSP systems. Two significant deviations expected in Gen3 systems compared to operating conditions used to build these models are particle impact velocities and system temperature. As a first step, the performance of these models was validated at low velocities and temperatures. Impact erosion experiments were conducted on SS316 coupons using HSP 40/70 ceramic particles. Assuming particle rate of 1 kg/s/m, 0.0254 m of particle curtain thickness, and particle velocity of 1.5 m/s in the system, an overall erosion of 0.59 mm/year was calculated. The experimental results were subsequently compared to those from computational simulations and erosion of 0.47 mm/year was obtained using the Arabnejad et al. model. The results indicated that the models work well at low velocities and low temperature conditions. To account for temperature effect, a mathematical correlation was developed using data published by DUCOM [3] for Inconel 600 eroded by alumina particles at high velocities. The correlation was applied to both Arabnejad et. al model and the E/CRC model. The prediction results from these modified models were within 20% of this experimental data. Predictions of of erosion by the modified E/CRC model at three different temperatures are made. Similar to the calculation at low temperature, a typical CSP system with 1 kg/s/m of particle flow rate per unit length of the particle curtain and a curtain thickness of 0.0254 m is assumed. The annual thickness loss calculations were run for different particle impact velocities, assuming a uniform particle impact area equal to the cross-sectional area of the curtain (particle-particle interactions and dispersion of particles are not considered in obtaining the results). It is observed that erosion increases exponentially as temperature increases. Furthermore, it is also noted that, erosion changes non-linearly with impact velocity. Currently, experiments are also being conducted to measure erosion of SS316 at 800 ºC with HSP 40/70 particles at low impact velocities. We expect to use the results from high temperature testing to further improve the temperature correlation function. Similar models are also being developed for abrasion erosion resulting from particle sliding along the surfaces as well as attrition from particle to particle and particle to surface interactions. References. [1] Institute, A. P. (1991). API Recommended Practice for Design and Installation of Offshore Production Platform Piping System, API RP 14E. [2] Arabnejad, H., Mansouri, A., Shirazi, S. A., and McLaury, B. S. (2015a). Development of mechanistic erosion equation for solid particles. Wear, 332–333, 1044–1050. http://doi.org/10.1016/j.wear.2015.01.031. [3] https://ducom.com/high-temperature-erosion-evaluating-sample-wear/

14 SOLAR ENERGY↗
DOE OSTI2020

Falling particle impact erosion testing for particle based CSP systems

CSP systems are currently being examined as an effective method for using solar energy to generate electricity. While much of this research has been conducted using molten salt as the heat transfer medium, in recent years, solid particles have been posited as a cheaper and more energy efficient heat transfer medium for use in CSP systems. Many researchers have looked into the effectiveness of solid particles as a heat transfer medium. However, a concern with the use of particles is that the falling particles will impact various components within the CSP system, such as the hopper, the heat exchanger, and the insulating material, resulting in surface erosion and damage. With repeated impacts from falling particles, material from the surfaces under impact is removed. The degree of erosion depends on whether the substrate is made of brittle or ductile material. Furthermore, factors such as particle shape, size, hardness, concentration, impact angle, particle velocity, and substrate hardness will contribute to the erosion process and determine how much and how quickly erosion will takes place in a system. Three types of erosion will be observed simultaneously: impact erosion from particle impact on receiver, particle storage, and heat exchanger walls, abrasion erosion from particle sliding motion along walls, and attrition erosion as the particles breakdown from particle-to-particle contact and particle-to-wall interactions. It is imperative to understand each of these erosions individually for a more comprehensive understanding and prediction of CSP system durability. In this work, we developed an experimental test setup capable of measuring impact erosion at conditions relevant to 1MW CSP plant. Subsequently, Impact erosion measurements were performed for three different candidate substrate materials at low particle velocities using HSP 40/70 ceramic particles.

14 SOLAR ENERGY↗
DOE OSTI2020

Experimental testing of particle attrition in CSP systems at high temperature

An alternate and sustainable form of energy is CSP systems, which capture and store the sun’s energy in the form of heat. Increasing the operational temperature of CSP systems will increase the efficiency of electricity production while operating at temperatures exceeding 700 degrees Celsius also creates novel operational problems. One approach for high-temperature CSP systems is to utilize solid particles as the primary heat transfer medium. As particles flow through this system, the movement of particles creates erosion in the forms of impact, abrasion, and attrition erosion. In the real world, while all three forms of erosion will occur simultaneously, it is imperative to understand the individual effect of each erosion over the lifetime of the powerplant. Besides material erosion and long-term durability concerns, thermal cycling of the particles could also introduce changes in particle thermal performance due to alterations in particle morphology. Current research on the issue of erosion has been limited to industrial applications and does not necessarily coincide with the operating conditions in CSP systems. We focus on attrition erosion resulting from particle-to-wall and particle-to-particle interactions. Research has shown that besides material hardness affecting how fast particles break down, attrition erosion increased as the size of the particles increased due to a higher chance of collision between the particles. Particle attrition is relevant to the CSP community as it may result in material loss, change the system's thermal performance, and generation of fines which could pose an environmental hazard. In this work, we focus on developing a test set up that can isolate and measure particle attrition when subjected to conditions relevant to Gen3 CSP systems.

14 SOLAR ENERGY↗
DOE OSTI2020

Boride-Carbon Hybrid Technology to Produce Ultra-Wear and Corrosion Resistant Surfaces for Applications in Harsh Conditions (Final Technical Report)

Engineered functional surfaces play an important role to enable new products and manufacturing processes that can endure harsh service conditions such as high impact and contact loads, highly abrasive wear, extreme temperatures, and corrosive environments. Engineered surfaces can also be instrumental to improving the efficient use of energy by reducing frictional losses and extending service life. The main objective of this project was to develop a hybrid surface engineering technology that combines the advantages of a novel ultrafast boriding process with the next generation of superhard carbon coatings. The hypothesis was that this hybrid process will offer an unprecedented combination of wear and corrosion resistance, low frictional losses and affordability for treated parts so that it can be utilized in many applications. During this project, a duplex process was developed that combines the advantages of ultra-fast electrochemical boriding with those of hard tetrahedral amorphous carbon coatings. Both technologies can be combined to form a hybrid technology that is characterized by low friction and wear properties combined with corrosion and fatigue resistance. Good adhesion of both layers to each other was one main goal of this project, that has been achieved with HF1 adhesion through the Rockwell-C adhesion test. In this project, the mechanical properties of the hybrid coating were modeled through a finite-element analysis approach. We can conclude that the FEA model resembles the actual samples and be utilized to predict mechanical behavior under impacts. Based on this model, application-oriented load conditions can be simulated for optimal layer design regarding thickness and mechanical properties. To exemplify, one conclusion that can be drawn from the nanoindentation model is a boride layer thickness of 50 µm is sufficient to effectively support the carbon coating on the identified AISI 1045 low carbon steel substrate material. The duplex treatment yields wear rates as low as 6 x 10 -8 mm 3 N -1 m -1 and a coefficient of friction of 0.14 when tested against a steel counter face in a ball-on-disk test setup. On the other hand, the wear rate of the only-borided AISI 1045 steel was 5 x 10 -5 mm 3 N -1 m -1 , about three orders of magnitude higher than the duplex coating. At the same time, duplex treated samples experience corrosion resistance, which could not be achieved with single-layer carbon coatings. The developed surface treatment withstands a 3-hour exposure to 15% HCl, while the only carbon coated counter sample shows severe delamination of the coating due to pin hole corrosion. The boride layer is chemically stable and pin hole free because it is formed through an electrochemical process under high current densities (700 mA/cm 2 ) and high temperature. Additionally, the hybrid coating led to at least 3x increase in fatigue strength of the steel substrate, which exceeds the target performance of 30% improvement. There are numerous potential applications for the duplex coatings. A representative application is bearing ball coatings for off-shore windmills. Compared to currently employed surface technologies in this field, the initial costs of applying our technology might be higher due to more process steps but the performance benefits lead to an increased life time of treated parts, which will lower the maintenance and replacement costs in the long-term. To validate the technology for this specific application, the team is currently investigating the process of white etching crack initiation of the duplex coating in collaboration with ANL. Overall, this project successfully validated that the boride-carbon hybrid technology can withstand harsh conditions. One possible approach to commercialization under consideration is to transfer the technology to a startup or an existing coatings company.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Additive Manufacturing of Corrosion Resistant UHTC Materials for Chloride Salt-to-sCO2 Brayton Cycle Heat Exchangers

The objectives of the project include: (1) screen high-purity, high density ultra-high-temperature ceramics (UHTCs) for chloride salt corrosion resistance, (2) develop binder-jet additive manufacturing and sintering for ZrB 2 -MoSi 2 blends using literature and experiments to demonstrate feasibility, and (3) evaluate chloride salt corrosion resistance of additively manufactured ZrB 2 -MoSi 2 . These initial objectives support the development of a durable and reliable ultra-compact high-efficiency salt-to-sCO 2 heat exchanger for closed-loop Brayton power cycles based on corrosion resistant, high-strength, thermally conductive UHTC materials and novel designs enabled by additive manufacturing. The UHTC materials are also abrasion resistant so that they could be applicable to all three thermal carrier media pathways identified in the CSP Gen3 Roadmap.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Laser-Interference Surface Preparation for Enhanced Coating Adhesion and Adhesive Joining of Multi-Materials (Final Project Report)

This report investigates a laser-interference surface treatment as a non-contact, i.e., without major solid/liquid medium application or abrasion, and non-chemical surface preparation method for aerospace coating systems. It was proposed to use the laser-interference technique to structure surfaces of Al and/or Ti, creating "rough" surfaces with pre-engineered series of ridges and valleys at submicron scale. The science goal of this study was to develop an understanding of the surface microstructure, topology, and physical mechanisms that would improve adhesion and corrosion protection of Al2024-T3. Microstructure analysis indicates that the laser-interference structuring (LIS) was found to reduce the formation of CuMn-rich precipitates in Al 2024-T3 over a 500-800 nm depth from top surface. The X-cut and cross-hatch coating adhesion ratings indicate that the LIS specimens meet the performance requirements in the coating adhesion specifications by having a higher or identical ranking to those specimens prepared with current state-of-the-art chemical conversion or sulfuric acid anodizing. After the ASTM B117 corrosion exposure, it was found that the laser processed specimens exhibited only few blisters. It was found that the corrosion damage was minimized at a laser rastering speed of 4 mm/s, for which only 33% of specimens developed very minor corrosion damage. The ASTM D1654 creepage ratings, used to evaluate corrosion damage along the scribe lines, were found to be at least nine for all coated panels. These results indicate that the laser-interference technique with the additional acetone wiping has the potential to be further developed as a minor chemical surface preparation technique for chromate-containing epoxy primers coatings.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Advanced Reaction System Program: Materials for ARS Reaction Chambers (FY18 Milestone, Subtask 3.3)

The objective of this effort is to identify materials and manufacturing technology that will allow the rapid construction and evaluation of computer modeled advanced reactor system designs to process specific carbon feedstock materials. Before full scale reaction systems can be built, prototypes need to be constructed and operated to validate the proposed new system performance against target criteria. The first steps, however, are to understand what type of materials are needed that can withstand the targeted process environments and determine how structures using those materials can be built. A wide range of reaction vessel conditions may exist in the processes being considered that could involve temperatures up to 1200°C, abrasive materials (high velocity coal and coal ash), different carbon feedstock materials (coal, biomass, and process wastes such as petcoke), corrosive and oxidizing/reducing gases, different material phases (solid, liquid, and gas), cyclic temperatures, microwave energy, customized vessel construction material needs (process stability, cost, weight, and compatibility with other materials), along with other known/unknown variables – all of which must be considered in selecting materials and considering manufacturing processes. The current focus of the research is to develop a reaction vessel sidewall structure consisting of a metal outer support and an inner ceramic (or cermet) protective surface. Ceramic coatings are desired because of their good corrosion and wear resistance, and because they are the material of choice to reduce metal shell temperature in high temperature processes. However significant property mismatches between metals and ceramics have been a roadblock to the joining of metals and ceramics.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Phase I DOE DE-SC0021823 Entitled “Changing the Design Rules of Rubber to Create Lighter Weight, More Fuel Efficient Tires” Final Technical Report 04/08/2022

Molecular Rebar Design, LLC has successfully developed new rubber composites with individualized carbon nanotubes called MOLECULAR REBAR® (MR), improving tire tread compound performance for use with electric vehicles (EVs). Through the iterative nature of the Phase I experimentation, MRD developed a novel carbon nanotube material that disperses well with other typical tire compound fillers and can be chemically functionalized for unique material property benefits. The new MR material is a chemically functionalized, discrete multi-wall carbon nanotube that binds into the rubber compound using silane technology. This Molecular Rebar based tire tread material drastically improves DIN abrasion resistance 25%+ (correlating to improved tire life), reduces tread weight by 6-7%, and reduces rolling resistance 20%+ (correlating to improved energy efficiency), as compared to an in-use, state-of-the-art, silica-silane tread compound. The formulations can be adjusted to maximize energy efficiency, to maximize wear or to have a blend of improvement depending on the tire performance needs of end use customers.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Two-Step Synthesis of Poly (urea formaldehyde) Microcapsules

Self-healing coatings have potential to reduce waste and minimize repair costs in industries where materials need to be protected from harsh environmental conditions and mechanical abrasion. These coatings can be created by embedding healing-agent filled microcapsules which release their contents and fill voids in the event of damage. To synthesize microcapsules that are ideal for self-healing coatings, they must have a diameter less than 100 microns, smooth surface morphology, and have improved dispersibility. Our current one-step method does not produce microcapsules within the desired size distribution, so a two-step route where oligomers of the shell wall material are formed prior to microcapsule formation was investigated. This was done by evaluating the effects of solution viscosity, size of reaction vessel, addition of poly (vinyl alcohol) (PVA), and core/shell ratio on microcapsule properties. Characterization of microcapsule size, morphology, and composition was done using optical microscopy, Fourier-transform infrared spectroscopy (FTIR), and thermogravimetric analysis (TGA). Microcapsules with an average diameter of 78 ± 16 microns were successfully synthesized. Further work must be done to minimize PUF crystallites on the surface of the microcapsules.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Advanced Anti-Fouling Coatings to Improve the Efficiency of Coal Power Plants

As the total cost of carbon to generate energy has become a global concern, operators are increasingly looking at all parts of the generation cycle to find areas where efficiency gains may be found. It has been long identified that fouling of heat exchangers is a persistent cause of up to 2.5% of global CO 2 emissions. Unfortunately, practice has also demonstrated that unless a powerful economic driver exists to encourage preemptive mitigation of fouling, there will always be a strong tendency for operators to minimize any form of intervention due to high costs and challenges in scheduling downtime. The objective of this proposed research effort was to demonstrate how existing power plants could lower their carbon emissions and significantly improve heat transfer efficiency using new surface treatment materials to control fouling in a variety of heat exchange equipment. The surface treatment material which was optimized and deployed in this effort is now known commercially as HeatX. It is a low-surface energy, water- and oil-repellent, abrasion resistant material which can be applied in-situ to a wide variety of previously worn/used/in-service substrates. Once applied, it provides a barrier against corrosion, scale deposit formation, and biofilm adhesion on the circulating water-containing tube-side. Alternatively, if applied to the tube exterior, the non-wetting nature of the surface was demonstrated to promote dropwise condensation, subsequently lowering condenser backpressure and increasing overall plant efficiency. As part of this cooperative effort, the Department of Energy’s support was crucial to de-risk and demonstrate the concept of HeatX, while validating both the performance and economic benefit in multiple pilot field studies. The HeatX material properties were optimized in this effort for full field applicability to heat exchangers and condensers, and Oceanit developed the necessary procedures and protocols to provide enough material to support extended length, multi-year demonstrations in the power generation, desalination, and refining industries, making this technology broadly applicable and ready for commercial transition. Field deployment case studies at thermal power plants have shown that the HeatX treatment can provide economic savings of up to $15,000 per day for an operator based on avoiding maintenance costs and lowering fuel usage. The complete mitigation of fouling effects can increase the efficiency of equipment by up to 7%, in a field where gains of 0.5% are generally seen as operationally significant. The HeatX treatment has also demonstrated exceptional lifetime and compatibility with a wide variety of seawater and hydrocarbon environments, further increasing both the return on investment and the effective emission reduction. Such efficiency improvements correlate to massive carbon savings. For every 1 GW of capacity, operators can see carbon emissions reductions of 300,000 tons of CO 2 per year. When looking at the bigger picture, improved condenser function across the U.S. has the potential to prevent 221.3 million tons of CO 2 emissions, equivalent to the sequestration capacity of 129 million acres of forest. If applied on a global scale, 1.26 billion metric tons of CO 2 could be averted from the atmosphere, the same amount of carbon sequestrated by 1.5 billion acres of forest annually or 262,000 wind turbines operating annually. As businesses across multiple industries take a more active role in focusing on environmental, social, and governance (ESG) solutions as part of their core business operations, HeatX will be an attractive technology for commercial investment.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2023

Initial Assessment of Erosion/Abrasion Issues Related to Gas-Cooled Reactors

The US Department of Energy’s Oak Ridge National Laboratory (ORNL) is investigating the graphite erosion concern detailed in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code (BPVC), Section III, Division 5, “High Temperature Reactors.” The special consideration in Subsection HH, Subpart A (HHA)-3143, “Abrasion and Erosion,” was described in ASME BPVC Section III, Division 5, which was accepted with exception/limitation in a US Nuclear Regulatory Commission (NRC) Technical Review. This report describes ORNL’s FY 2023 comprehensive research of erosion-related reports and publications to further study the proposed gas flow velocity limitation to the erosion effect in graphite structure in the ASME BPVC. This report also proposes that a nondimensional fluid parameter, the Reynolds number, might be a better alternative than gas flow velocity for comparing erosion effects caused by carbonaceous dust in fast-flowing helium coolant in gas-cooled reactors (GCRs).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗