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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 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Corrosion Resistance of an AlCeMg/Stainless-Steel Reactive Bond

A major issue for metal components in many industries is corrosion as it can substantially reduce their lifetime. This issue is especially problematic for materials used in heat exchanger applications. Al–Ce–Mg alloys, which exhibit corrosion resistance and can reactively bond with other metals, may be a viable solution to this problem. This investigation studied the corrosion behavior of Al–2Ce–6Mg (atomic percent)/stainless-steel (SS) reactive bond interfaces after full immersion in nitric, sulfuric, formic, and mixed acid for 267 h. This particular Al–Ce–Mg alloy was chosen due to its good castability. The results of scanning electron microscope characterization showed that reactive bond formations repeatedly occurred throughout the length of the casting in the as-cut samples and that these formations maintained a secure bonding between the alloy and the stainless-steel tubes. Transmission electron microscopy results showed that there was a clear compositional and microstructural transition across the reactive bond. The results of the immersion tests indicated that the nitric, sulfuric, and the mixed acid did not have an observably negative effect on the reactive bond structure. As for the sample exposed to formic acid only, noticable changes were seen in both the microstructural appearance and the elemental profile across the bond, suggesting that oxide formation occurred.

Brechtl, Jamieson [ORNL] (ORCID:0000000217394283)↗
NASA NTRS1990

Fracture-tough, corrosion-resistant bearing steels

The fundamental principles allowing design of stainless bearing steels with enhanced toughness and stress corrosion resistance has involved both investigation of basic phenomena in model alloys and evaluation of a prototype bearing steel based on a conceptual design exercise. Progress in model studies has included a scanning Auger microprobe (SAM) study of the kinetics of interfacial segregation of embrittling impurities which compete with the kinetics of alloy carbide precipitation in secondary hardening steels. These results can define minimum allowable carbide precipitation rates and/or maximum allowable free impurity contents in these ultrahigh strength steels. Characterization of the prototype bearing steel designed to combine precipitated austenite transformation toughening with secondary hardening shows good agreement between predicted and observed solution treatment response including the nature of the high temperature carbides. An approximate equilibrium constraint applied in the preliminary design calculations to maintain a high martensitic temperature proved inadequate, and the solution treated alloy remained fully austenitic down to liquid nitrogen temperature rather than transforming above 200 C. The alloy can be martensitically transformed by cryogenic deformation, and material so processed will be studied further to test predicted carbide and austenite precipitation behavior. A mechanistically-based martensitic kinetic model was developed and parameters are being evaluated from available kinetic data to allow precise control of martensitic temperatures of high alloy steels in future designs. Preliminary calculations incorporating the prototype stability results suggest that the transformation-toughened secondary-hardening martensitic-stainless design concept is still viable, but may require lowering Cr content to 9 wt. pct. and adding 0.5 to 1.0 wt. pct. Al. An alternative design approach based on strain-induced martensitic transformation during cryogenic forming, thus removing the high martensitic constraint, may permit alloy compositions offering higher fracture roughness.

Olson, Gregory B.↗
NASA NTRS1966

Treatment increases stress-corrosion resistance of aluminum alloys

Overaging during heat treatment of the aluminum alloys immediately followed by moderate plastic deformation, preferably by shock loading achieves near optimum values of both yield strength and resistance to stress corrosion. Similar results may be obtained by substituting a conventional deformation process for the shock loading step.

Jacobs, A. J.↗
NASA NTRS1981

Corrosion resistant thermal barrier coating

A thermal barrier coating system for protecting metal surfaces at high temperature in normally corrosive environments is described. The thermal barrier coating system includes a metal alloy bond coating, the alloy containing nickel, cobalt, iron, or a combination of these metals. The system further includes a corrosion resistant thermal barrier oxide coating containing at least one alkaline earth silicate. The preferred oxides are calcium silicate, barium silicate, magnesium silicate, or combinations of these silicates.

Levine, S. R.↗
NASA NTRS1988

Castable hot corrosion resistant alloy

Some 10 wt percent nickel is added to an Fe-base alloy which has a ferrite microstructure to improve the high temperature castability and crack resistance while about 0.2 wt percent zirconium is added for improved high temperatur cyclic oxidation and corrosion resistance. The basic material is a high temperature FeCrAl heater alloy, and the addition provides a material suitable for burner rig nozzles.

Charles A. Barrett↗
NASA NTRS2015

60NiTi Intermetallic Material Evaluation for Lightweight and Corrosion Resistant Spherical Sliding Bearings for Aerospace Applications

NASA Glenn Research Center and the Kamatics subsidiary of the Kaman Corporation conducted the experimental evaluation of spherical sliding bearings made with 60NiTi inner races. The goal of the project was to assess the feasibility of manufacturing lightweight, corrosion resistant bearings utilizing 60NiTi for aerospace and industrial applications. NASA produced the bearings in collaboration with Abbott Ball Corporation and Kamatics fabricated bearing assemblies utilizing their standard reinforced polymer liner material. The assembled bearings were tested in oscillatory motion at a load of 4.54kN (10,000 lb), according to the requirements of the plain bearing specification SAE AS81820. Several test bearings were exposed to hydraulic fluid or aircraft deicing fluid prior to and during testing. The results show that the 60NiTi bearings exhibit tribological performance comparable to conventional stainless steel (440C) bearings. Further, exposure of 60NiTi bearings to the contaminant fluids had no apparent performance effect. It is concluded that 60NiTi is a feasible bearing material for aerospace and industrial spherical bearing applications.

materials↗
DOE OSTI2026

Corrosion Resistance of Lignin-Based Thermoplastic Adhesive-Bonded Aluminum Joints

Adhesive-bonded joints are essential for lightweight, multimaterial automotive structures. We developed a lignin-based thermoplastic adhesive with adhesion strength comparable to conventional epoxy adhesives (20–23 MPa), while offering exceptional durability, recyclability, and corrosion resistance. Unlike commercial epoxy adhesives requiring refrigerated storage, our adhesive retains its bonding potential after a year of ambient conditioning. Bonded joints can be repeatedly disassembled and rejoined with less than 2% strength loss. After 500 h of salt fog exposure, the adhesive-bonded aluminum joints exhibited a 24% strength reduction, compared to 61% reduction in strength of joints based on a commercial epoxy adhesive.

Yu, Zeyang [ORNL] (ORCID:0000000209002374)↗
NASA NTRS2015

60NiTi Intermetallic Material Evaluation for Lightweight and Corrosion Resistant Spherical Sliding Bearings for Aerospace Applications, Report on NASA-Kamatics SAA3-1288

Under NASA Space Act Agreement (SAA3-1288), NASA Glenn Research Center and the Kamatics subsidiary of the Kaman Corporation conducted the experimental evaluation of spherical sliding bearings made with 60NiTi inner races. The goal of the project was to assess the feasibility of manufacturing lightweight, corrosion resistant bearings utilizing 60NiTi for aerospace and industrial applications. NASA produced the bearings in collaboration with Abbott Ball Corporation and Kamatics fabricated bearing assemblies utilizing their standard reinforced polymer liner material. The assembled bearings were tested in oscillatory motion at a load of 4.54 kN (10,000 lb), according to the requirements of the plain bearing specification SAE AS81820. Several test bearings were exposed to hydraulic fluid or aircraft deicing fluid prior to and during testing. The results show that the 60NiTi bearings exhibit tribological performance comparable to conventional stainless steel (440C) bearings. Further, exposure of 60NiTi bearings to the contaminant fluids had no apparent performance effect. It is concluded that 60NiTi is a feasible bearing material for aerospace and industrial spherical bearing applications.

friction↗
NASA NTRS1992

Use of cyclic current reversal polarization voltammetry for investigating the relationship between corrosion resistance and heat-treatment induced variations in microstructures of 400 C martensitic stainless steels

Software for running a cyclic current reversal polarization voltammagram has been developed for use with a EG&G Princeton Applied Research Model 273 potentiostat/galvanostat system. The program, which controls the magnitude, direction and duration of an impressed galvanostatic current, will produce data in ASCII spreadsheets (Lotus, Quattro) for graphical representation of CCRPV voltammograms. The program was used to determine differences in corrosion resistance of 440 C martenstic stainless steel produced as a result of changes in microstructure effected by tempering. It was determined that tempering at all temperatures above 400 F resulted in increased polarizability of the material, with the increased likelihood that pitting would be initiated upon exposure to marine environments. These results will be used in development of remedial procedures for lowering the susceptibility of these alloys toward the stress corrosion cracking experienced in bearings used in high pressure oxygen turbopumps used in the main engines of space shuttle orbiters.

Ambrose, John R.↗
NASA NTRS1985

Internal stresses in wear and corrosion resistant amorphous metallic coatings of (W/0.6/Re/0.4/)76B24 and (Mo/0.6/Ru/0.4/)82B18

Hard protective coatings in the W-Re-B and Mo-Ru-B alloy systems have been deposited by magnetron sputtering onto soda-lime glass and heat-treated AISI 52100 steel substrates. X-ray diffraction has confirmed the amorphous nature of the as-deposited coatings, and their crystallization temperatures were determined by differential thermal analysis to be 1000 and 790 C for W-Re-B and Mo-Ru-B coatings, respectively. Both coatings exhibit high microhardness; Mo-Ru-B, in addition, has excellent corrosion resistance by comparison with pure Mo at high anodic potentials. Attention is given to the influence of internal stresses on the protective properties of the coatings deposited under different conditions.

Thakoor, A. P.↗
NASA NTRS1959

Halogen-Containing Gases as Boundary Lubricants for Corrosion-Resistant Alloys at 1200 F

The extreme temperatures anticipated for lubricated parts in advanced flight powerplants dictate the consideration of unconventional methods of lubrication such as solid lubricants and the reactive gases described in the present research. These halogen-containing "reactive" gases such as dichlorodifluoromethane, CF2Cl2, are among the most stable of organic molecules. The high "flash" temperatures generated at the contacting asperities as a result of frictional heat are sufficient to cause local decomposition of the halogen-containing gases. The active atoms thus released (e.g., chlorine) then react with the metal to be lubricated to form halides capable of effective lubrication. The presence of small amounts of a sulfur-containing gas (e.g., 1 percent sulfur hexafluoride, SF6) was found to catalyze the formation of metal halides. Friction and wear studies were made with a hemisphere (3/16-in. rad.) rider sliding in a circumferential path on the flat surface of a rotating disk (2 1/2-in. diam.). The specimens of corrosion-resistant 2 alloys were run in an atmosphere of the various gases with a load of 1200 grams, a sliding velocity of 120 feet per minute, and temperature from 75 to 1200 F. An effective lubricant for ferritic materials (M-1 tool steel) was CF2Cl2, but significant corrosion occurred above 600 F. Corrosion evaluation in CF2Cl2 suggested a number of nickel- and cobalt-base alloys for additional lubrication study. Several combinations of gases and these metals were found to lubricate to 1200 F without excessive corrosion. The gases were CF2Cl2 Plus 1 percent SF6, monobromotrifluoromethane CF3Br plus 1 percent SF6, dibromodifluoromethane CF2Br2, iodotrifluoromethane, CF3I, and I2. Careful selection of metals and gas are necessary for successful lubrication over specific temperature ranges. Optimum combinations give friction coefficients as low as 0.05 without

Buckley, Donald H.↗
NASA NTRS2010

Corrosion-Resistant Container for Molten-Material Processing

In a carbothermal process, gaseous methane is passed over molten regolith, which is heated past its melting point to a temperature in excess of 1,625 C. At this temperature, materials in contact with the molten regolith (or regolith simulant) corrode and lose their structural properties. As a result, fabricating a crucible to hold the molten material and providing a method of contact heating have been problematic. Alternative containment approaches use a large crucible and limit the heat zone of the material being processed, which is inefficient because of volume and mass constraints. Alternative heating approaches use non-contact heating, such as by laser or concentrated solar energy, which can be inefficient in transferring heat and thus require higher power heat sources to accomplish processing. The innovation is a combination of materials, with a substrate material having high structural strength and stiffness and high-temperature capability, and a coating material with a high corrosion resistance and high-temperature capability. The material developed is a molybdenum substrate with an iridium coating. Creating the containment crucible or heater jacket using this material combination requires only that the molybdenum, which is easily processed by conventional methods such as milling, electric discharge machining, or forming and brazing, be fabricated into an appropriate shape, and that the iridium coating be applied to any surfaces that may come in contact with the corrosive molten material. In one engineering application, the molybdenum was fashioned into a container for a heat pipe. Since only the end of the heat pipe is used to heat the regolith, the container has a narrowing end with a nipple in which the heat pipe is snugly fit, and the external area of this nipple, which contacts the regolith to transfer heat into it, is coated with iridium. At the time of this reporting, no single material has been found that can perform the functions of this combination of materials, and other combinations of materials have not proven to be survivable to the corrosiveness of this environment. High-temperature processing of materials with similar constituencies as lunar regolith is fairly common. The carbo-thermal process is commonly used to make metallurgical-grade silicon for the semiconductor and solar-cell industries.

Stern, Theodore G.↗
DOE OSTI2026

Understanding the high-temperature behavior and corrosion resistance of Cr-Nb coated cladding for BWRs

While Cr-coated Accident Tolerant Fuel has proven successful in Pressurized Water Reactors, its dissolution in high dissolved oxygen Boiling Water Reactor environments represents a major technological barrier. Here, this study presents a comprehensive evaluation of novel Cr-Nb alloys as a coating breakthrough solution for Accident Tolerant Fuel cladding in Boiling Water Reactors. We systematically investigated Physical Vapor Deposited Cr-Nb coatings with 13% and 24 at% Nb content on commercial Zr-based cladding through rigorous testing under both normal and accident conditions. Our results demonstrate Cr-Nb coatings remained completely intact during extended Boiling Water Reactor autoclave testing, while pure Cr coatings failed catastrophically due to oxide dissolution. Under Loss-of-Coolant Accident conditions at 1100°C, Cr-Nb coatings maintained protective capability for 45 min. At 800°C, the alloy coatings matched pure Cr's excellent corrosion resistance. Despite microstructural changes during prolonged high-temperature exposure, no coating delamination occurred, ensuring continued protection of the underlying Zr substrate. These findings establish Cr-Nb coatings as a viable Accident Tolerant Fuel solution for Boiling Water Reactors.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1998

Comparative Stress Corrosion Cracking and General Corrosion Resistance of Annealed and Hardened 440 C Stainless Steel - New Techniques in Stress Corrosion Testing

The corrosion and stress corrosion cracking (SCC) characteristics of annealed and hardened 440C stainless steel were evaluated in high humidity and 3.5-percent NaCl solution. Corrosion testing consisted of an evaluation of flat plates, with and without grease, in high humidity, as well as electrochemical testing in 3.5-percent NaCl. Stress corrosion testing consisted of conventional, constant strain, smooth bar testing in high humidity in addition to two relatively new techniques under evaluation at MSFC. These techniques involve either incremental or constant rate increases in the load applied to a precracked SE(B) specimen, monitoring the crack-opening-displacement response for indications of crack growth. The electrochemical corrosion testing demonstrated an order of magnitude greater general corrosion rate in the annealed 440C. All techniques for stress corrosion testing showed substantially better SCC resistance in the annealed material. The efficacy of the new techniques for stress corrosion testing was demonstrated both by the savings in time and the ability to better quantify SCC data.

Mendreck, M. J.↗