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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

Emerging Opportunities in Manufacturing Bulk Soft-Magnetic Alloys for Energy Applications: A Review

Abstract Soft-magnetic alloys exhibit exceptional functional properties that are beneficial for a variety of electromagnetic applications. These alloys are conventionally manufactured into sheet or bar forms using well-established ingot metallurgy practices that involve hot- and cold-working steps. However, recent developments in process metallurgy have unlocked opportunities to directly produce bulk soft-magnetic alloys with improved, and often tailorable, structure–property relationships that are unachievable conventionally. The emergence of unconventional manufacturing routes for soft-magnetic alloys is largely motivated by the need to improve the energy efficiency of electromagnetic devices. In this review, literature that details emerging manufacturing approaches for soft-magnetic alloys is overviewed. This review covers (1) severe plastic deformation, (2) recent advances in melt spinning, (3) powder-based methods, and (4) additive manufacturing. These methods are discussed in comparison with conventional rolling and bar processing. Perspectives and recommended future research directions are also discussed.

36 MATERIALS SCIENCE↗

Evaluating the intrinsic resistance to balling of alloys: A High-throughput physics-informed and data-enabled approach

To date, the vast majority of work on metal additive manufacturing (AM) has been framed in terms of the need to tune processing conditions for a particular AM technology in order to print conventional alloys, oftentimes developed for fabrication methods other than AM. This approach overlooks the fact that historically, many engineering alloy system has been designed with a particular processing route in mind, e.g., ingot metallurgy, powder metallurgy, rapid quenching, etc. There are thus significant opportunities to design alloys specifically for AM. A key challenge is that alloy design requires performance metrics that can be optimized by exploring the alloy chemistry space. Here, we present a study in which we examine how intrinsic thermophysical properties can be used to estimate performance metrics related to the behavior of a solidifying metal droplet under AM-relevant conditions. By identifying these intrinsic properties, it is possible to directly incorporate ‘intrinsic printability’, specifically ‘intrinsic resistance to balling’, into AM-focused alloy design.

20 FOSSIL-FUELED POWER PLANTS↗

A comparison of wrought and powder metallurgical FeCrAl claddings under simulated LWR accident transients

Iron-chromium-aluminum (FeCrAl) alloys are potential accident tolerant fuel (ATF) cladding candidates for light-water reactors but are difficult to fabricate as thin-walled tubes via conventional cast-and-wrought routes. Powder metallurgy (PM) offers a manufacturing alternative with improved compositional control, but its transient accident performance has not been directly benchmarked against wrought variants. This study evaluates the burst behavior of commercially developed PM-processed FeCrAl alloys, PM-C26M (Fe-12Cr-6Al-2Mo) and the high precipitate density FA-SMT (Fe-22Cr-5Al-3Mo), under simulated light-water reactor accident transient conditions. Burst testing was conducted using the Severe Accident Test Station with heating rates of 5 °C/s and 50 °C/s and internal pressures ranging from 25 MPa to 100 MPa. PM-C26M reproduced wrought C26M burst behavior within 7–37 °C across the stress range, indicating that PM processing does not compromise transient strength. FA-SMT exhibited markedly higher burst temperatures and reduced heating-rate sensitivity, consistent with its engineered precipitate strengthening. FA-SMT rupture exhibited axial "unzipping" rather than the lateral tearing characteristic of PM- and wrought C26M. Post-test EBSD and fractography indicate that this behavior is strongly correlated with strain-gated intergranular void nucleation associated with the dense precipitate architecture of FA-SMT, a response absent in the comparatively clean PM-C26M matrix and consistent with rupture morphologies reported for oxide-dispersion strengthened (ODS) FeCrAl of similar base-matrix chemistry to PM-C26M. These findings highlight the potential of powder metallurgy as a viable fabrication route for ATF claddings from an accident performance standpoint.

Bell, Sam [ORNL] (ORCID:0000000251905657)↗

Thermomechanical Properties of Hafnium Hydride for Radiation Shielding in Tokamak Devices

The development of effective neutron shielding materials is of paramount importance for the progression of fusion technologies with the aim of producing clean and sustainable energy for future generations. This study demonstrates the successful fabrication of a promising candidate material for shielding applications, hafnium hydride, through the powder metallurgy process. Powder metallurgy fabrication resulted in the production of 91% dense, crack-free, ε-phase HfH 2 pellets with a hydrogen-to-metal ratio of 1.89 to 2.00. Resonant ultrasound spectroscopy (RUS) was used to measure a Young’s modulus of 34.52 ± 2.70 GPa and a shear modulus of 12.25 ± 0.18 GPa. Nanoindentation techniques have been used to establish a hardness value of 4.45 ± 1.63 GPa, and a Young’s modulus of 47.8 ± 6.4 GPa was determined using Poison’s ratio from RUS. Hydrogen release was measured using thermogravimetric analysis and appeared to occur in three different regimes as the sample transitioned through the ε- and δ-phases. Heat capacity matched literature data up to 600 K, after which a rapid increase was observed due to phase transformations occurring with hydrogen loss.

Hafnium hydride↗

Development of an immersion fiber optic Raman probe for real-time analysis of molten materials

This study presents an advancement in high-temperature Raman spectroscopy, specifically for analyzing molten materials. It introduces an approach by integrating a fiber-optic Raman probe with a copper block protection system designed to endure extreme thermal conditions. The copper block features an open port designed to accommodate an external telescope with a 3 cm focal length, enabling Raman spectra collection in challenging high-temperature environments. A built-in gas channel ensures a continuous flow of argon gas to prevent flux intrusion. The robust copper block acts as a reliable shield, safeguarding the fiber-optic Raman probe within molten materials. This enhancement maintains the probe's integrity and significantly improves its resilience, making it ideal for rigorous investigations of molten substances. This advancement is particularly relevant in metallurgy, where flux materials impact production quality and efficiency. The ability to acquire Raman signals under elevated thermal conditions offers opportunities for studying molecular dynamics, compositional changes, and chemical interactions within molten substances. This introduced direct immersion probing technique has implications, benefiting both scientific and industrial fields. It holds promise for advancing research and exploration in various contexts, from fundamental scientific inquiries to practical applications in metallurgical processes, where flux materials are critical for optimizing production quality and efficiency. Furthermore, this approach enhances the capabilities of high-temperature Raman spectroscopy, making it a valuable tool for investigating molten materials and their properties in diverse settings.

Argon↗

Process Intensification for Nanostructure Aluminum Extrusions

A new technology called Shear Assisted Processing and Extrusion (ShAPE™), pioneered at the Pacific Northwest National Laboratory (PNNL), has the potential to revolutionize the US extrusion industry. Maturation of the ShAPE™ process would create a new cross cutting US manufacturing technology that advances three key the objectives within AMO; namely, nanomaterials processing, process intensification, and materials for extreme and harsh environments. PNNL and SCM Metals Products, Inc. (SCM), a division of Kymera International, will collaborate to mature the ShAPE™ extrusion process beyond TRL 3 to increase the likelihood of its adoption by industry. PNNL’s custom (one-of-a-kind in the world) ShAPE™ machine will be used to extrude round rods of high strength aluminum alloy feedstock powder provided by SCM. As proof-of-concept, PNNL has previously extruded 5 mm diameter rods with SCM aluminum alloy powder AL-12.4TM. This project aims to scale up the process to a diameter of 25 mm while retaining the excellent mechanical properties achieved for the 5 mm diameter rods. The degree of process intensification with ShAPE™ will also be estimated. The primary objectives of this project are as follows. 1) Fabricate 25 mm diameter nanostructured extrusions in bulk, directly from AL-12.4TM aluminum alloy powder without the need for canning, degassing, compaction, and other intermediate steps typical of powder metallurgy extrusion. 2) Achieve a microstructure with an ultrafine grained (UFG <1 µm) aluminum matrix having refined and homogenously distributed nanoscale second phases. 3) Show that the ram force can be significantly reduced compared to conventional powder metallurgy extrusion of the same material and estimate the extent of process intensification that may be possible with ShAPE™. 4) Demonstrate improved high-temperature mechanical properties compared to conventional extrusion of the same material. The following tasks will be undertaken to achieve these objectives. PNNL will develop the die set and process parameters necessary to fabricate Al-12.4TM extrusions with a 25 mm diameter. Microstructural analysis will be performed by PNNL while mechanical testing will be conducted by SCM. With information learned from the process development and characterization, PNNL will perform an estimate of the degree of process intensification that may be possible with ShAPE™.

42 ENGINEERING↗

Boosting the Strength and Electrical Conductivity of Aluminum Alloys

It is common practice to use pure copper as the material of choice in applications requiring adequate strength and high electrical conductivity (EC). However, the overwhelming increase in the cost and worldwide demand for copper is becoming a major concern. As the move towards electrification throughout the world is occurring, so is a parallel move to make aluminum (Al) and Al alloys suitable as a replacement for copper. To make this goal a reality, exploration into enhancements in the strength and EC of high conductivity Al alloys is necessary. This study compiles strength and EC data for current Al powder metallurgy (PM) alloys to better understand existing data and target future research. Also highlighted are reviews of completed research projects, including studies relating to liquid metallurgy, by industry professionals and academia, noting both shortcomings and successes.

Imbrogno, Peter↗

Hydrogen Permeation in FeCrAl APMT Alloy for Accident Tolerant Fuel Cladding

Iron-chromium-aluminum (FeCrAl) alloys such as APMT (advanced powder metallurgy tubing) are candidate materials to replace zirconium alloys for the light water reactor fuel cladding. This alloy meets the requirements to be a material more tolerant of high-temperature accidents than the current zirconium alloys. One concern is that the use of FeCrAl may result in an increase in tritium presence in the coolant compared to the current design. The aim of the current research was to obtain effective diffusion coefficients (D eff ) for hydrogen through APMT using the Devanathan-Stachurski cell. Results showed that at 30°C the D eff value was 2.8 × 10 -8 cm 2 /s. Results also showed a linear relationship between the permeated hydrogen flux and the inverse of the test specimen thickness, which demonstrated the validity of the permeation measurements.

36 MATERIALS SCIENCE↗

Efficient separation and coprecipitation for simplified cathode recycling

Hydrometallurgical recycling of spent lithium-ion batteries is among the most promising recovery approaches. The current hydrometallurgical method for battery recycling faces challenges such as complex separation and precipitation processes, and environmental concerns from the use of caustic inorganic acid and hazardous hydrogen peroxide. Our proposed modified method, namely polyol-metallurgy, uses citric acid in ethylene glycol as dual-function green solution to overcome these obstacles. This bifunctional solution leaches valuable metal ions from cathode materials (e.g., LiCoO 2 ), and then acts as chelating agents to selectively precipitate cobalt through an esterification reaction, without the need for additional precipitation agents. The leaching efficiency of cobalt and lithium reaches 99.55% and 97.65%, respectively, and more than 96% of cobalt could be directly self-precipitated and recovered. Further, the unique characteristics of the dual-function solution also avoids impurities from Al foils and PVDF/carbon black films, enabling the simple separation process. Therefore, the process can be completed in one-pot system with efficient leaching, separation and coprecipitation, making it more efficient and feasible for operation than existing alternatives.

25 ENERGY STORAGE↗

Diffusion and phase formation in the γ-uranium-technetium system

Phase formation in the U-Tc binary system at 800 °C was investigated using a diffusion couple experiment. Scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS) identified four novel potential intermetallic phases - U 7 Tc 3 , U 13 Tc 12 , U 3 Tc 5 , and UTc 4 . Diffusion coefficients were calculated for the intermetallic phases using the Boltzmann-Matano method and were respectively found to be – 120, 38.2, 15.6, and 1.51 × 10 −18 m 2 /s. Tc also exhibits a solid-solution phase with high penetration into the U with a diffusion coefficient of ∼ 10 −14 m 2 /s. Furthermore, these findings expand the number of known U-Tc phases and provide the first diffusion coefficients for the U-Tc system, and contribute valuable data to the broader field of actinide metallurgy.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Comparing structure-property evolution for PM-HIP and forged alloy 625 irradiated with neutrons to 1 dpa

The nuclear power industry has growing interest in qualifying powder metallurgy with hot isostatic pressing (PM-HIP) to replace traditional alloy fabrication methods for reactor structural components. But there is little known about the response of PM-HIP alloys to reactor conditions. This study directly compares the response of PM-HIP to forged Ni-base Alloy 625 under neutron irradiation doses ~0.5–1 displacements per atom (dpa) at temperatures ranging ~321–385 °C. Post-irradiation examination involves microstructure characterization, ASTM E8 uniaxial tensile testing, and fractography. Up through 1 dpa, PM-HIP Alloy 625 appears more resistant to irradiation-induced cavity nucleation than its forged counterpart, and consequently experiences significantly less hardening. This observed difference in performance can be explained by the higher initial dislocation density of the forged material, which represents an interstitial-biased sink that leaves a vacancy supersaturation to nucleate cavities. These findings show promise for qualification of PM-HIP Alloy 625 for nuclear applications, although higher dose studies are needed to assess the steady-state irradiated microstructure.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

The Influence of Strain Path and Heat Treatment Variations on Recrystallization in Cold-Rolled High-Purity Niobium Polycrystals

With the standard material and cavity production guidelines, the properties and performance of industrially produced high-purity niobium superconducting radiofrequency (SRF) cavities are unpredictably variable. Currently, assembled niobium SRF cavities undergo post-purification vacuum heat treatment at 800 °C for three hours to remove hydrogen and increase performance; however, recent work has shown significant improvements in cavity performance when annealed between 900–1000 °C, causing recrystallization (Rx). Increasing the annealing temperature and/or the heating rate should facilitate the onset of Rx, resulting in a greater reduction in the density of geometrically necessary dislocations (GNDs) that are strongly associated with the degradation of cavity performance via trapped magnetic flux. Improving the SRF community's understanding of the influence of both heat treatment and deformation history on the resulting microstructure and Rx behavior in high-purity niobium is needed. This fundamental metallurgy is critical for identifying improved specifications for the consistent production of high-performing niobium SRF cavities. This research investigates variations in deformation paths, heating rates, and annealing temperatures on Rx of deformed samples of polycrystalline high-purity niobium. To assess the effects of strain path, samples were cold-rolled to ~30% reduction prior to annealing, with half of the sample set rolled parallel to the as-received niobium sheet and the other half in the transverse direction.

36 MATERIALS SCIENCE↗

Low Cost HIP Fabrication of Advanced Power Cycle Components and PM/Wrought Inconel 740H Weld Development (Final Technical Report)

The objective of this Phase 1 project is to demonstrate the feasibility of structures and components for advanced fossil energy power cycle by fusion welding powder metallurgy (PM) based near net shape (NNS) hot isostatic pressing (HIP) Nickel superalloy Inconel 740H (IN740H) components to wrought IN740H components. The outcome of the project includes a prototype pipe elbow demonstration of the NNS HIP process using IN740H powder, an initial assessment of IN740H PM/wrought weldability, and a manufacturing and capital cost analysis of IN740H NNS HIP components for advanced ultra-super critical steam (AUSC) power plants. The anticipated value proposition of NNS HIP manufacturing is ~50% cost reduction of large complex components in AUSC or super-critical carbon dioxide (sCO2) power cycles. This document is a final technical report for the project, covering efforts conducted from October 2019 to June 2021.

20 FOSSIL-FUELED POWER PLANTS↗

LANL/UTEP Metallurgical Science Center of Excellence Planning

LANL seeks research assistance and skills development in three distinct subject areas over the next three years. Individualized scope and detail implementation schedules will be the first deliverable for these subject areas and will represent a joint determination between LANL SMEs and UTEP faculty based on LANL priority (schedule) and UTEP staffing (faculty and student- graduate and undergraduate) and capability of immediate availability per schedule. LANL will endeavor to make summer internships available to UTEP students within these subject areas: Chemical Sciences, Additive Manufacturing, and Metallurgy: casting and solidification, characterization, and metal purification. Unarticulated but generalized scoping tasks follow within each topical area to indicate that students and technicians familiar with these skill sets are of value and interest in LANL workforce pipeline and the tasks that seek to develop these skill sets are intentional on LANL's part. Consequently, LANL will sponsor 2-3 senior (capstone) projects within these subject areas per year over the three year time period within these task areas and within separations technologies, wet chemical analysis, and analytical characterization and quantification as required by all tasks.

36 MATERIALS SCIENCE↗

Fabrication of ceramic to metal graded structure for high temperature CSP receiver application using solid state additive manufacturing

The overarching goal of this project is to come up with an innovative joining solution for integration of SiC ceramic to structural materials such as stainless steels (SS)/Ni-base alloys, where intimate metallurgical bonding between SiC ceramic and the structural metallic alloy is demonstrated at the interface. Implementation of a simple, yet robust joining method would help in increasing the application space of SiC in a high-temperature CSP (concentrated solar power) plant, especially in the receiver section. This research goal has been achieved by creating a functionally graded material (FGM) interface between SiC and the selected structural material with the help of powder metallurgy (PM) approach and demonstrate intimate metallurgical bonding between monolithic RB-SiC and 316L stainless steel alloy blanks.

36 MATERIALS SCIENCE↗

Elevated-temperature cyclic properties of advanced manufactured materials

Microreactor developers at the 2019 GAIN Microreactors workshop expressed a need for advanced manufacturing to fabricate microreactor components. Powder metallurgy (PM) hot isostatic pressing (HIP) is more mature than other advanced manufacturing techniques for the following reasons: 1. a code case exists for Section III, Division 1, Subsection NB components of light water reactors to be manufactured using PM HIP Alloy 316L, and 2. tensile and creep properties have been shown to be equivalent to wrought material for Type 316 stainless steel and Grade 91. Thus, PM HIP is more readily deployable in the near term. Elevated-temperature cyclic properties of PM-HIP materials, however, have not been established. The scope of testing for Code qualification could be significantly reduced compared to a new material for the following reasons: 1. only a limited amount of time consuming creep testing would be required, and 2. testing of fatigue and creep-fatigue behavior could be reduced if it can be demonstrated that the properties are comparable to wrought material. The objective of this work package is to develop an understanding of the relationship of advanced materials processing on the material characteristics as they relate to elevated-temperature component design and construction. This will be achieved by the following: • Elevated-temperature fatigue and creep-fatigue testing of PM HIP and wrought Alloy 316L. • Fracture and microstructural characterization of the PM HIP and wrought Alloy 316L. • Analysis of the elevated-temperature fatigue and creep-fatigue properties of PM HIP Alloy 316L. • Draft a report evaluating the elevated-temperature fatigue and creep-fatigue properties of PM HIP Alloy 316L. • Pursue procurement of Alloy 316H and Grade 91 manufactured using PM HIP. • Initiate scoping studies of the procured Alloy 316H or Grade 91 manufactured using PM HIP contingent upon successful material procurement.

36 MATERIALS SCIENCE↗

Microreactors Electrify the Future of Mining

This presentation is for the Joint Coeur d’Alene and Columbia Basin meeting of the Society for Mining, Metallurgy & Exploration on May 12. The presentation briefly defines microreactor technology, potential markets, provide an example of a remote mining case study in Alaska, describes ways to extend the product value chain, presents a concept for a microreactor powered integrated mining operation, and describes Environmental, Social and Governance (ESG) considerations in mining.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

A Preliminary Radiological Risk Assessment Model for Disposition of Remote-Handled Transuranic Wastes at Los Alamos National Laboratory Area G - 20116

The U.S. Department of Energy (DOE) operates a low-level radioactive waste (LLW) disposal site at Material Disposal Area G, in Los Alamos, New Mexico, USA. Area G has been the primary LLW disposal site for Los Alamos National Laboratory (LANL) since the 1960's. In addition to LLW, Area G is host to a variety of other wastes, the disposition of which must be determined before closure of the site. A probabilistic Radiological Risk Assessment (RRA) for Area G is used in order to support decision making regarding some wastes that are not addressed in the extant Area G Performance Assessment (PA) and Composite Analysis (CA). Between 1979 and 1987, 33 special shafts were augered into the Bandelier Tuff at Area G. This volcanic tuff is present across Pajarito Plateau on the eastern slopes of the Jemez Mountains, and varies widely in its consistency, from weakly indurated non-welded layers to welded layers that uphold the mesa cliffs of the Plateau. These mesas are home to LANL, Area G, and the townsites of Los Alamos and White Rock, with residences about 1400 m from Area G. The 33 Shafts were lined with steel casing, and contain remote-handled (RH) transuranic wastes (TRU) resulting from experiments and analysis performed in special glove boxes at the Chemistry and Metallurgy Research (CMR) facility at LANL. Some of these wastes originated as used nuclear fuel. The purpose of the Area G RRA is to evaluate the potential future risk to humans and the environment from the RH TRU in the 33 Shafts in the context of the risk associated with the surrounding wastes at Area G. The analysis is responsive to expectations outlined in DOE Order 458.1, Radiation Protection of the Public and the Environment, and is informed by the Manual and Guidance accompanying DOE O 435.1, Radioactive Waste Management. Because the waste meets the definition of TRU, the regulatory context necessarily takes into consideration the regulation governing the disposal of TRU from the U.S. Environmental Protection Agency (EPA): 40 CFR 191, Environmental Radiation Protection Standards for Management and Disposal of Spent Nuclear Fuel, High-Level and Transuranic Radioactive Wastes. Given the broader regulatory context for the RRA, the analysis is subject to different assumptions from those made in the existing DOE O 435.1 PA and CA, such as allowing for future occupation of the site. The analysis begins with a comprehensive evaluation of features, events, processes, and exposure scenarios (FEPS) for Area G and the wastes it contains. These FEPSs are screened to eliminate from further consideration those of extremely low probability and/or consequence, and a conceptual site model (CSM) is subsequently developed. The scope and structure of the Area G RRA Model is informed by this CSM, and the Area G RRA Model is developed using the GoldSim systems analysis modeling platform. This paper presents the initial version of a defensible, transparent, and reasonably realistic model, which is based on the state of knowledge of the wastes, the site, and the FEPSs that govern contaminant transport from wastes into the environment and subsequent exposures to humans and other biota. Probabilistic model input distributions represent uncertainties inherent in the real and modeled systems. The results of the Area G RRA Model inform decisions regarding the disposition of the RH TRU in the 33 Shafts. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗