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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 OSTI2022

Assessing the interfacial corrosion mechanism of Inconel 617 in chloride molten salt corrosion using multi-modal advanced characterization techniques

The United States Department of Energy (DOE) has committed to expanding the domestic clean energy portfolio in response to the rising challenges of energy security in the wake of climate change. Accordingly, the construction of a series of Generation IV reactor technologies are being demonstrated, including sodium-cooled, small modular, and molten chloride fast reactors (MCFRs). To date, there are no fully qualified structural materials for constructing MCFRs. A number of commercial structural alloys have been considered for the construction of MCFRs, including alloys from the Inconel and Hastelloy series. Informed qualification of structural materials for the construction of MCFRs in the future can only be ensured by expanding the current fundamental knowledgebase of information pertaining to material performance under environmental stressors relevant to operation of the reactor, including corrosion susceptibility. The purpose of this investigation is to illustrate how a correlative multi-modal electron microscopy characterization approach, including the novel application of focused-ion beam 3D reconstruction capabilities, can elucidate the corrosion mechanism of a candidate structural material Inconel 617 for MCFR in NaCl-MgCl 2 eutectic salt at 700°C for 1,000 h. Evidence of intergranular corrosion, Ni and Fe dealloying, and Cr-O enrichment along the grain boundary, which most likely corresponds to Cr 2 O 3 , is a phenomenon that has been documented in other Ni-based superalloys exposed to chloride molten salt systems. Additional corrosion products, including the formation of insoluble MgAl 2 O 4 , within the porous network produced by the salt attack is a novel observation. In addition, Mo 3 Si 5 and τ 2 precipitates are detected in the alloy bulk and are dissolved by the salt. Furthermore, the lack of detection of design γ' precipitates in Inconel 617 after 1,000 h could indicate that the molten salt corrosion mechanism has indirectly induced a phase transformation of Al 2 TiNi (τ 2 ) and Ni 3 (Al,Ti) (γ’) phase. This investigation provides a comprehensive understanding of molten salt corrosion mechanisms in a complex material system such as a commercial structural alloy for applications in MCFRs.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Microstructural basis for improved corrosion resistance of laser surface processed AZ31 Mg alloy

Despite their excellent strength to weight ratio, wider use of Mg alloys for light weighting applications is limited by their poor corrosion resistance, especially in chloride ion-containing environments. The present study shows improved corrosion resistance imparted by laser surface processing (LSP) of a commercial AZ31 (Mg-3Al-1Zn) alloy. Nanosecond laser processing at three different power settings was carried out on the surface of a 1 mm thick rolled AZ31 sheet. Corrosion testing based on ASTM B117 method and several other electrochemical tests indicates substantial enhancement of corrosion resistance in LSP-treated AZ31. The underlying reason behind improved corrosion resistance of LSP-AZ31 surface has been identified using a variety of characterization tools (SEM, TEM, XPS). Formation of a ~0.5 µm thick mixed metal (Mg, Al) oxide surface film together with refinement in the size and number density of Al-Mn intermetallic particles appear to be playing a major role towards improved corrosion resistance after LSP treatment of AZ31 alloy.

Jana, Saumyadeep↗
DOE OSTI2018

Decoupling the role of stress and corrosion in the intergranular cracking of noble-metal alloys

Intergranular stress-corrosion cracking (IGSCC) is a form of environmentally induced crack propagation causing premature failure of elemental metals and alloys. It is believed to require the simultaneous presence of tensile stress and corrosion; however, the exact nature of this synergy has eluded experimental identification. For noble metal alloys such as Ag–Au, IGSCC is a consequence of dealloying corrosion, forming a nanoporous gold layer that is believed to have the ability to transmit cracks into grain boundaries in un-dealloyed parent phase via a pure mechanical process. Here using atomic-scale techniques and statistical characterizations for this alloy system, we show that the separate roles of stress and anodic dissolution can be decoupled and that the apparent synergy exists owing to rapid time-dependent morphology changes at the dealloyed layer/parent phase interface. We discuss the applicability of our findings to the IGSCC of important engineering Fe- and Ni-based alloys in critical applications.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Effects of calcium in ash on the corrosion performance of Ni-based alloys in simulated oxy-fuel environment

Increasing the efficiency of coal power plants requires raising the operating temperature above 650°C. However, coal ash can severely attack alloy materials at high temperature. For example, the corrosion rates of commercial Fe- and Ni-based alloys are generally greater than 2 mm/year at 750°C in the gas environment of oxy-fuel combustion. Thus, a critical study is needed to determine the effect of the constituents in the ash on corrosion and find an approach to reduce the corrosion rates in an ash-laden environment at high temperature. The role of CaO in the ash (typical of U.S. Western coal ash) has been investigated in laboratory exposure environments with various structural alloys. Detailed results are presented on weight change, scale thickness, internal penetration, microstructural characteristics of corrosion products, and the cracking of scales for the alloys after exposure at 750°C. The thermal stability of K3Al(SO4)3 under the environment of oxy-fuel combustion was determined by thermogravimetric analysis and differential thermal analysis. The reaction of this low melting temperature salt with the CaO-containing ash is discussed. In addition, we performed synchrotron nanobeam X-ray analysis to study the phase and chemical composition of the oxide layers on the alloy surface. Results from these studies are used to address the role of CaO in ash in the long-term corrosion performance of alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2020

The Sporadic History of Rubidium and its Role in Corrosion of Steel Related to Nuclear Material Storage

The influence of rubidium (Rb), both in its metallic and oxidized states, on the corrosion resistance of steels has direct relevance to the storage of radioactive Kr-85 containing nuclear materials. Kr-85 undergoes a ß-decay to generate stable, metallic Rb. The literature to date is sparse, contained primarily in company reports and divisive as to whether Rb metal, or its oxides, can lead to corrosion of steel materials. In both the direct storage of Kr-85 and used nuclear fuel that will contain Kr-85, if Rb is corrosive then continual decay of the Kr-85 will generate an increasingly corrosive environment for the steel canister it is stored in. This review was written to consolidate the known data to date on Rb corrosion of steels to identify consistencies, contradictions and remaining gaps in our understanding of the Rb : steel system.

krypton, corrosion, steel, Rubidium↗
DOE OSTI2018

Corrosion Resistance and Durability of Superhydrophobic Copper Surface in Corrosive NaCl Aqueous Solution

Artificial superhydrophobic copper surfaces play an important role in modern applications such as self-cleaning and dropwise condensation; however, corrosion resistance and durability often present as major concerns in such applications. In this study, the anti-corrosion properties and mechanical durability of superhydrophobic copper surface have been investigated. The superhydrophobic copper surfaces were achieved with wet chemical etching and an immersion method to reduce the complexity of the fabrication process. The surface structures and materials were characterized using scanning electron microscope (SEM), energy dispersive X-ray spectroscopy (EDX), and Fourier transform infrared spectrometer (FTIR). The corrosion resistance and mechanical properties of the superhydrophobic copper surface were characterized after immersing surfaces in a 3.5 wt % NaCl solution. The chemical stability of the superhydrophobic copper surface in the NaCl solution for a short period of time was also evaluated. An abrasion test and an ultrasound oscillation were conducted to confirm that the copper surface contained durable superhydrophobic properties. In addition, an atomic force microscope was employed to study the surface mechanical property in the corrosion conditions. The present study shows that the resulting superhydrophobic copper surface exhibit enhanced corrosion resistance and durability.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2018

Grain boundary selective oxidation and intergranular stress corrosion crack growth of high-purity nickel binary alloys in high-temperature hydrogenated water

The effects of alloying elements in Ni-5at%X binary alloys on intergranular (IG) corrosion and stress corrosion cracking (SCC) have been assessed in 300-360°C hydrogenated water at the Ni/NiO stability line. Alloys with Cr or Al additions exhibited grain boundary oxidation and IGSCC, while localized degradation was not observed for pure Ni, Ni-Cu or Ni-Fe alloys. Environment-enhanced crack growth was determined by comparing the response in water and N2 gas. Results demonstrate that selective grain boundary oxidation of Cr and Al promoted IGSCC of these Ni alloys in hydrogenated water.

Environmental Molecular Sciences Laboratory↗
DOE OSTI2022

Pitting Corrosion in 316L Stainless Steel Fabricated by Laser Powder Bed Fusion Additive Manufacturing: A Review and Perspective

Abstract 316L stainless steel (316L SS) is a flagship material for structural applications in corrosive environments, having been extensively studied for decades for its favorable balance between mechanical and corrosion properties. More recently, 316L SS has also proven to have excellent printability when parts are produced with additive manufacturing techniques, notably laser powder bed fusion (LPBF). Because of the harsh thermo-mechanical cycles experienced during rapid solidification and cooling, LPBF processing tends to generate unique microstructures. Strong heterogeneities can be found inside grains, including trapped elements, nano-inclusions, and a high density of dislocations that form the so-called cellular structure. Interestingly, LPBF 316L SS not only exhibits better mechanical properties than its conventionally processed counterpart, but it also usually offers much higher resistance to pitting in chloride solutions. Unfortunately, the complexity of the LPBF microstructures, in addition to process-induced defects, such as porosity and surface roughness, have slowed progress toward linking specific microstructural features to corrosion susceptibility and complicated the development of calibrated simulations of pitting phenomena. The first part of this article is dedicated to an in-depth review of the microstructures found in LPBF 316L SS and their potential effects on the corrosion properties, with an emphasis on pitting resistance. The second part offers a perspective of some relevant modeling techniques available to simulate the corrosion of LPBF 316L SS, including current challenges that should be overcome.

Voisin, T. (ORCID:0000000287462659)↗
DOE OSTI2021

Mechanistic insights into selective oxidation and corrosion of multi-principal element alloys from high resolution and in situ microscopy

Multiple principal elements alloys (MPEAs) have drawn significant recent interest from the metallurgical research community. These novel alloys have the potential to replace traditional alloys with a range of tailored mechanical properties, corrosion resistance, and radiation tolerance enabled by complex compositions. The broad alloy design space of MPEAs presents a great opportunity to discover new forms of oxidation and corrosion resistance in extreme environments that break away from conventional corrosion resistant alloy design criteria. However, understanding the oxidation and corrosion response of MPEAs can be a challenging task due the complex composition, structural, and chemical state changes occurring in the corrosion product and at its interface with the base alloy. This perspective discusses the utility of high resolution and in situ microscopy techniques for revealing unique aspects of MPEA oxidation behavior at the near-atomic level. Challenges of studying these alloys and several open questions are presented.

Kautz, Elizabeth J.↗
DOE OSTI2022

Laboratory Accelerated Cyclic Corrosion Testing and On-Road Corrosion Testing of AA6××× Coupled to Carbon Fiber-Reinforced Plastics

Structures made from a combination of aluminum alloy (AA) and carbon fiber-reinforced plastic (CFRP) are susceptible to galvanic corrosion of the AA in harsh atmospheric conditions, such as might exist for closure panels in automotive applications. It is important to understand the galvanic corrosion behavior of these materials under laboratory conditions as that might allow prediction of performance in real environments. This work tested specially designed AA6×××-CFRP coupons, including AA6111 and AA6022, connected to CFRP made from two different carbon fiber fabrics (twill and random) with the aim of understanding the corrosion behaviors in a laboratory cyclic exposure chamber and during on-road exposure. The extent of corrosion was assessed by galvanic current measurements, optical profilometry, cross-sectional area analysis, and microscopic analysis. Based on the results, it was determined that the corrosion susceptibilities and morphologies observed in CFRP/AA couples tested in an environmental chamber for 12 weeks were in correspondence with those of the coupons subjected to on-road testing for 1 y in Columbus, OH.

Materials Science↗
NASA NTRS1982

Review of corrosion causes and corrosion control in a technical facility

Causes of corrosion of metals and their alloys are reviewed. The corrosion mechanism is explained by electrochemical reaction theory. The causes and methods of controlling of both physiochemical corrosion and biological corrosion are presented. Factors which influence the rate of corrosion are also discussed.

Charng, T.↗
NASA NTRS1985

Corrosion and corrosion prevention in gas turbines

The conditions governing the corrosion behavior in gas turbines are surveyed. Factors such as temperature, relative humidity, the presence of sulfur and nitrogen dioxide, and fuel quality are discussed. Electromechanical corrosion at relatively low temperature in compressors; oxidation; and hot corrosion (sulfidation) at high temperature in turbines are considered. Corrosion prevention by washing and rinsing, fueld additives, and corrosion resistant materials and coatings are reviewed.

Mom, A. J. A.↗
NASA NTRS1928

Corrosion Embrittlement of Duralumin II Accelerated Corrosion Tests and the Behavior of High-Strength Aluminum Alloys of Different Compositions

The permanence, with respect to corrosion, of light aluminum alloy sheets of the duralumin type, that is, heat-treatable alloys containing Cu, Mg, Mn, and Si is discussed. Alloys of this type are subject to surface corrosion and corrosion of the interior by intercrystalline paths. Results are given of accelerated corrosion tests, tensile tests, the effect on corrosion of various alloying elements and heat treatments, electrical resistance measurements, and X-ray examinations.

Rawdon, Henry S↗
DOE OSTI2019

Real time numerical computation of corrosion rates from corrosion sensors

A method for determining a corrosion rate includes receiving an input signal including corrosion data from a sensor. A signal-to-noise ratio (SNR) and a type of noise is determined from the input signal. A corrosion rate computation method is selected based on the SNR and the type of noise. The corrosion rate is determined, using a processor, based on a selected corrosion rate computation method.

Klein, Levente I.↗
DOE OSTI2020

Real time numerical computation of corrosion rates from corrosion sensors

A method for determining a corrosion rate includes receiving an input signal including corrosion data from a sensor. A signal-to-noise ratio (SNR) and a type of noise is determined from the input signal. A corrosion rate computation method is selected based on the SNR and the type of noise. The corrosion rate is determined, using a processor, based on a selected corrosion rate computation method.

36 MATERIALS SCIENCE↗
DOE OSTI2017

In Situ X-ray Microtomography of Stress Corrosion Cracking and Corrosion Fatigue in Aluminum Alloys

Structural materials are subjected to combinations of stress and corrosive environments that work synergistically to cause premature failure. Therefore, studies on the combined effect of stress and corrosive environments on material behavior are required. Existing studies have been performed in two dimensions that are inadequate for full comprehension of the three-dimensional (3D) processes related to stress corrosion cracking (SCC) and corrosion-fatigue (CF) behavior. Recently, x-ray synchrotron tomography has evolved as an excellent technique to obtain the microstructure in 3D. Moreover, being nondestructive in nature, x-ray synchrotron tomography is well suited to study the evolution of microstructure with time (4D, or fourth dimension in time). Furthermore, this article presents our recent 4D studies on SCC and CF of Al 7075 alloys using x-ray synchrotron tomography.

36 MATERIALS SCIENCE↗