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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 73 records · Page 4

Hydrogen in disordered titania: connecting local chemistry, structure, and stoichiometry through accelerated exploration

Hydrogen incorporation in native surface oxides of metal alloys often controls the onset of metal hydriding, with implications for materials corrosion and hydrogen storage. A key representative example is titania, which forms as a passivating layer on a variety of titanium alloys for structural and functional applications. These oxides tend to be structurally diverse, featuring polymorphic phases, grain boundaries, and amorphous regions that generate a disparate set of unique local environments for hydrogen. Here, we introduce a workflow that can efficiently and accurately navigate this complexity. First, a machine learning force field, trained on ab initio molecular dynamics simulations, was used to generate amorphous configurations. Density functional theory calculations were then performed on these structures to identify local oxygen environments, which were compared against experimental observations. Second, to classify subtle differences across the disordered configuration space, we employ a graph-based sampling procedure. Finally, local hydrogen binding energies and hopping kinetics are computed using exhaustive density functional theory calculations on representative configurations. Here, we leverage this methodology to show that hydrogen binding energetics are described by local oxygen coordination, which in turn is affected by stoichiometry, and form the basis of hopping kinetics and diffusion. Together these results imply that hydrogen incorporation and transport in TiO x can be tailored through compositional engineering, with implications for improving the performance and durability of titanium-derived alloys in hydrogen environments.

36 MATERIALS SCIENCE↗

Real-time monitoring of trace noble gases using laser-induced breakdown spectroscopy—An investigation of the impact of bulk gas on plasma properties and sensitivity

The impact of Ar and He bulk gases on laser-induced breakdown spectroscopy (LIBS) real-time monitoring of trace Xe and Kr was assessed. LIBS is being developed as a monitoring tool for measuring noble gas transport in molten salt systems, in which traditional sensors may face challenges associated with radiation, corrosive materials, and/or mixed phases. The plasma temperature and electron densities of LIBS plasmas were measured in both static and various flowing Ar and He streams (0–5 L min −1 ). The use of an Ar bulk gas resulted in higher plasma temperature, greater electron densities by an order of magnitude, and extended plasma lifetime compared with when He bulk gas was used. Gas flow rate was found to have little impact on plasma temperature; however, its effect on electron density was significant, indicating the need to consider flow rate–specific models. Matrix effects on emission peaks were reported for both bulk gases. Due to these matrix effects, multivariate models were developed for Xe and Kr ranging from 0 to 700 ppm in both bulk gases. Although the predictive behavior was similar (root mean square error of prediction ranging from 11.1 to 20.6 ppm), the limits of detection were superior in He (Xe: 22.9 ppm, Kr: 30.4 ppm). Furthermore, these models were employed in demonstrative real-time tests (>1 h), which showed strong predictive precision (relative standard deviation <5 %) regardless of the bulk gas. Ultimately, this study provides a guide for the considerations required when developing gaseous LIBS models for real-time monitoring.

Gas flow effects↗

Complexity of segregation behavior at localized deformation sites formed while in service in a 316 stainless steel baffle-former bolt

Here, post-irradiation evaluation was performed on a 316 stainless steel baffle former bolt harvested after 40 years of service in a pressurized water reactor. Microstructure analysis revealed the presence of defect-free dislocation channels and strain-induced twins, indicative of loading at a stress level close to yield stress at least once while in service. Primary radiation-induced Ni/Si precipitates were destroyed during channel and twin formation, and secondary, significantly coarser Ni/Si precipitates formed along newly formed Σ3 boundaries during the continued irradiation. Additionally, an elevated phosphorus level was observed inside the strain-induced twin. Complex chemistry inside the strain-induced feature may overlap with dislocation pileups and impact localized corrosion, material long-term performance, and safety.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Fundamental chemical physics revealed by scattering reactive open-shell atoms from surfaces

The dynamics of reactive atoms at surfaces are centrally important to areas such as heterogeneous catalysis, corrosion, materials degradation in extreme environments, and plasma etching. Remarkably detailed understanding of dynamical processes at surfaces has been extracted from scattering molecules and inert atoms under well-defined conditions. However, traditional techniques for generating beams of reactive atoms often result in impure mixtures, broad energy distributions, and poorly defined contributions of metastable electronically excited atoms. In this perspective article, we review the state-of-the-art in reactive atom surface scattering with a focus on experiments performed under controlled conditions on well-defined surfaces. We highlight a new technique for controlled state-to-state scattering of polyelectronic atoms from surfaces, based on vacuum ultraviolet photolysis and state-selective ion imaging. The new capabilities provide an avenue for research into the underexplored area of excited state and spin selective chemical dynamics at surfaces.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

Novel Tube Design for Superheater Heat Exchanger Enabled Via Additive Manufacturing

Superheater tubes are critical boiler components that operate at relatively higher temperatures and pressure. Amongst the primary concerns for these tubes is the deposition of ash particles on the tube surface, leading to the reduced thickness of the tube due to material corrosion, consequently causing early creep failure of the component. In this research, a novel tube design has been proposed which resembles a teardrop or ogive shape to reduce the drag and concurrently improve the creep life of the superheater tubes. To administer the practicality of novel tubes, metal additive manufacturing (AM), for instance, laser-powder bed fusion (L-PBF), has been proposed. These unconventional designs were assessed and compared with the baseline circular tube design for mechanical design requirements (hoop stress and creep life) and the particle and flue gas flow characteristics around the differently shaped tubes. A thermomechanical finite element (FE) analysis was performed for hoop stress calculations. This study also emphasizes on effect of circumferential thermal variation on hoop stress distribution in tubes. Therefore, a detailed two-dimensional (2D) thermal simulation has been performed to report the circumferential thermal variation on the tube. A computational fluid dynamics (CFD) analysis coupled with particle tracing was performed for gas flow visualization and particle tracing around the proposed shapes and baseline circular-shaped tube design. The Schlieren optic setup was built and leveraged for qualitative validation of the proposed design. The complete design methodology established in the paper shows teardrop-shaped tubes better in terms of drag and creep life in contrast to the circular-shaped tube.

42 ENGINEERING↗

Aqueous Titania Interfaces

Water–metal oxide interfaces are central to many phenomena and applications, ranging from material corrosion and dissolution to photoelectrochemistry and bioengineering. In particular, the discovery of photocatalytic water splitting on TiO 2 has motivated intensive studies of water-TiO 2 interfaces for decades. So far, a broad understanding of the interaction of water vapor with several TiO 2 surfaces has been obtained. However, much less is known about liquid water–TiO 2 interfaces, which are more relevant to many practical applications. Probing these complex systems at the molecular level is experimentally challenging and is sometimes possible only through computational studies. This review summarizes recent advances in the atomistic understanding, mostly through computational simulations, of the structure and dynamics of interfacial water on TiO 2 surfaces. The main focus is on the nature, molecular or dissociated, of water in direct contact with low-index defect-free crystalline surfaces. The hydroxyls resulting from water dissociation are essential in the photooxidation of water and critically affect the surface chemistry of TiO 2.

density functional theory↗

Testing of High S Matrix Glasses to Expand DFHLW Glass Compositional Ranges (Rev.1)

Gaps in glass composition-property data for direct-feed high-level waste (DFHLW) have recently been identified. One such gap is the region of high sulfur solubility since previous, pretreated, high-level wastes contained very little sulfur. Filling this data gap will significantly broaden the range of process flowsheet options including minimal washing and will allow for optimized waste loading in DFHLW glasses. This report summarizes the data collected during the characterization of the DFHLW High S Glass Matrix (HS24). A glass matrix of 50 glass compositions was developed to evenly cover the DFHLW composition region for high sulfur glass. Matrix glasses were designed to expand the composition region outside the current component concentration and property limits so as to reduce uncertainties at the limits. The 50 matrix glasses were fabricated and tested for properties important to the success of DFHLW vitrification including: compositions, canister centerline cooling (CCC) crystallinity and isothermal crystallinity, density, viscosity, electrical conductivity (EC), product consistency test (PCT) response, toxicity, and sulfate solubility. Melter materials corrosion testing is reported elsewhere. These glasses were intentionally designed to have high SO 3 solubilities (0.7 to 2.2 SO 3 wt%) in compositional regions that had not been previously explored. Forty-eight glasses showed the measured SO 3 content retained >80% of the target SO 3 and the densities of all the glasses ranged from 2.49 g·cm -3 to 2.74 g·cm -3 . While the model predicted nepheline formation in 5 glasses, one of the tested 50 CCC glasses formed nepheline, and 35 glasses formed Cr-containing phases such as spinels and eskolaite. Only five glasses were amorphous after CCC treatment where 44 glasses with detectable crystals contained =10 wt% crystals and only one glass had > 10 wt% crystals. None of the glasses exceeded the allowable T 2% for spinel crystal formation at 950 ºC (i.e., no glasses had >2 wt% spinel at 950 ºC) during isothermal crystal fraction tests where 10 glasses showed no crystalline phases at or below 950 ºC. All the glasses (except one which failed being slightly lower than the target) satisfied the SO 3 constraint while 98 glasses did not meet the viscosity constraints and 4 failed the EC constraints. Six quenched (Q) and six CCC glasses failed the Defense Waste Processing Facility (DWPF) Environmental Assessment (EA) glass PCT threshold and 3 Q and 4 CCC failed the PCT design constraint. One glass exceeded the WTP delisting limits for Cr via EPA Method 1311 (i.e., Toxicity Characteristic Leaching Procedure, TCLP). It should be emphasized that some of these glasses were specifically designed to approach or even exceed certain property constraints, as filling data gaps in these regions will provide the greatest benefit for future model development by improving accuracy and reducing uncertainties. These insights will ultimately support the development of more robust glass formulation strategies, enabling higher waste loading, reducing operational risks, and expanding the processing envelope.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Experimental Operation of a Prototype 750C Advanced Chloride Molten Salt Bellows Valve

To achieve DOE 2030 SunShot targets that reduce the cost of liquid-based solar by an additional 40% to 70% beyond 2018 costs, a more reliable, highly manufacturable flow valve, capable of achieving operational temperatures of >700°C is required [1]. This paper investigates the development of an innovative high-temperature chloride molten salt valve, with operation up to 750°C. This valve is intended to be employed within Gen 3 CSP liquid-based thermal energy storage (TES) systems as well as Gen 4 modular salt reactor (MSR) technologies. This work details the general design and flow testing of a bellows-seal flow control valve (FCV). This design includes an integrated closed-loop thermal control system to ensure robust design for freeze-thaw cycles. The self-contained thermal management STM system, is unique in the salt valve industry since it is an integrated solution to provide a consistent, repeatable alternative to typical heat tracing. Additionally, the design includes the employment of a novel heat pipe valve stem to facilitate enhanced passive thermal management into the valve assembly. This valve stem heat pipe is designed to facilitate natural circulation within the bonnet to ensure robust operation, during both nominal and transient thermal operation. The valve body and trim will be designed using SS316H, consistent with Flowserve Corporation’s existing product base and is code qualified but will utilize clad material for materials corrosion, manufacturing cost reduction and compatibility to ensure design flexibility. A test campaign was performed in this investigation utilizing a novel 750°C ternary chloride (20%NaCl/40%MgCl2/40%KCl by mol. wt. %) molten salt flow loop. A discussion about the design and installation of the valves within this test bed is provided for this investigation. Valve test results from this study assessed Cv curves as well as multiple actuator cycles, under varying thermodynamic and operational mode conditions, which would be characteristic within a commercial molten salt facility. The results indicate nominal operation for the baseline design, though improved performance and reliability is expected with the full designed FCV.

Armijo, Kenneth (ORCID:0000000346832147)↗

Design and development of a prototype wet oxidation system for the reclamation of water and the disposition of waste residues onboard space vehicles

Laboratory investigations to define optimum process conditions for oxidation of fecal/urine slurries were conducted in a one-liter batch reactor. The results of these tests formed the basis for the design, fabrication, and testing of an initial prototype system, including a 100-hour design verification test. Areas of further development were identified during this test. Development of a high pressure slurry pump, materials corrosion studies, oxygen supply trade studies, comparison of salt removal water recovery devices, ammonia removal investigation, development of a solids grinder, reactor design studies and bearing life tests, and development of shutoff valves and a back pressure regulator were undertaken. The development work has progressed to the point where a prototype system suitable for manned chamber testing can be fabricated and tested with a high degree of confidence of success.

Jagow, R. B.↗

The measurement of long period and secular deformation with deep borehole tiltmeters

Two clusters of instruments were emplaced in fractured bedrock in eastern Massachusetts in 1970 and 1975. The intrasite agreement at tidal periods was about two percent, but there is no agreement at longer periods. A strong temperature-induced annual component ranging from 3 to 15 urads was present on instruments installed at depths of 15-20m; it was not apparent on those at 100-120m. One instrument, in continuous operation for three years at 100m, showed a net drift of 0.3 urads down to the SW, with a maximum departure of 2.0 urads from the trend. Pore pressure variations, material corrosion and creep, and local movements are apparently the limiting factors to long-term measurements.

Cabaniss, G. H.↗

Heat storage capability of a rolling cylinder using Glauber's salt

The rolling cylinder phase change heat storage concept was developed to the point where a prototype design is completed and a cost analysis is prepared. A series of experimental and analytical tasks are defined to establish the thermal, mechanical, and materials behavior of rolling cylinder devices. These tasks include: analyses of internal and external heat transfer; performance and lifetime testing of the phase change materials; corrosion evaluation; development of a mathematical model; and design of a prototype and associated test equipment.

Herrick, C. S.↗

Site-Specific Research Conducted in Support of the Salton Sea Solar Pond Project - FY 1982 Report

The design and operation of a salt-gradient solar pond power plant at the Salton Sea presents problems not encountered at small research ponds that were built in the United States. The specific characteristics of the Salton Sea site and the desire to construct the pond using the local clay as a sealant represent major deviations from previous solar pond experience. The site-specific research in support of the plant design is described. The research activity included validation of the spectrophotometric light transmission measurement technique, a search for options for clarifying the turbid and colored water of the Salton Sea, development of water clarification specifications in terms common to industry practice, quantification of gas production from microbiological reactions in the ground, a determination of the combined effects of temperature and salinity on the permeation of the local clays, and a preliminary evaluation of material corrosion.

French, R. L.↗

Non-contaminating method to reduce Marangoni convection in microgravity float zones

A ground-based experiment has validated the effectiveness of a noncontaminating method developed to reduce Marangoni (thermal capillary) convection in float-zone processing of corrosive materials in space microgravity. A drop of silicone oil 1.5 mm high was enclosed in a transparent box, and the small size of the drop was shown to suppress the 1-g thermal-buoyant convection. A vertical jet of air was blown tangentially over a vertical free surface, producing a viscous shear drag which opposes the Marangoni surface shear. A 66 percent reduction in Marangoni velocities was found in the lowest one-third of the drop, corresponding to the resolidification surface in a float-zone melt.

Dressler, R. F.↗

Triton 2 (1B)

The goal of this project was to perform a detailed design analysis on a conceptually designed preliminary flight trainer. The Triton 2 (1B) must meet the current regulations in FAR Part 23. The detailed design process included the tasks of sizing load carrying members, pulleys, bolts, rivets, and fuselage skin for the safety cage, empennage, and control systems. In addition to the regulations in FAR Part 23, the detail design had to meet established minimums for environmental operating conditions and material corrosion resistance.

Clark, Michelle L.↗

Living Together in Space: The International Space Station Internal Active Thermal Control System Issues and Solutions-Sustaining Engineering Activities at the Marshall Space Flight Center From 1998 to 2005

On board the International Space Station, heat generated by the crew and equipment is removed by the internal active thermal control system to maintain a comfortable working environment and prevent equipment overheating. Test facilities simulating the internal active thermal control system (IATCS) were constructed at the Marshall Space Flight Center as part of the sustaining engineering activities to address concerns related to operational issues, equipment capability, and reliability. A full-scale functional simulator of the Destiny lab module IATCS was constructed and activated prior to launch of Destiny in 2001. This facility simulates the flow and thermal characteristics of the flight system and has a similar control interface. A subscale simulator was built, and activated in 2000, with special attention to materials and proportions of wetted surfaces to address issues related to changes in fluid chemistry, material corrosion, and microbial activity. The flight issues that have arisen and the tests performed using the simulator facilities are discussed in detail. In addition, other test facilities at the MSFC have been used to perform specific tests related to IATCS issues. Future testing is discussed as well as potential modifications to the simulators to enhance their utility.

Wieland, P. O.↗

Physics-informed machine learning assisted uncertainty quantification for the corrosion of dissimilar material joints

Jointing techniques like the Self-Piercing Riveting (SPR), Resistance Spot Welding (RSW) and Rivet-Weld (RW) joints are used for mass production of dissimilar material joints due to their high performance, short cycle time, and adaptability. However, the service life and safety usage of these joints can be largely impacted by the galvanic corrosion due to the difference in equilibrium potentials between the metals with the presence of electrolyte. Here, in this paper, we focus on Al-Fe galvanic corrosion and develop physics-informed machine learning based surrogate model for statistical corrosion analysis, which enables the reliability analysis of dissimilar material joints under corrosion environment. In this study, a physics-based finite element (FE) corrosion model has been developed to simulate the galvanic corrosion between a Fe cathode and an Al anode. Geometric and environmental factors including crevice gap, roughness of anode, conductivity, and the temperature of the electrolyte are investigated. Further, a thorough Uncertainty Quantification (UQ) analysis is conducted for the overall corrosion behavior of the Fe-Al joints. It is found that the electrolyte conductivity has the largest effects on the material loss and needs to be managed closely for better corrosion control. This will help in designing and manufacturing joints with improved corrosion performance.

42 ENGINEERING↗

Corrosion-Resistant Plug Materials for Geothermal Well Fluid Control

Conventional cements and plugs are challenged by corrosion in CO 2 -rich and extreme geothermal environments, due to the hostile chemistry and high temperatures. Thermite-based sealing and well intervention technologies are being applied in the oil and gas industry, combining the energy delivery capability of thermite materials with the sealing characteristics of low melt temperature alloys. The thermite reaction products (ceramics) and the sealing alloys used in these plugs both have very attractive corrosion properties, and their operating envelopes extend into geothermal conditions. Thermite plugs and platforms, without supplemental sealing materials, have been considered for nuclear waste isolation, carbon sequestration, and geothermal applications due to the geochemical stability of the ceramic product and its very high service temperature. This study addresses corrosion resistance of the thermite reaction products. A range of engineered thermite systems which yield thermite reaction products including pure aluminum oxide, feldspar, or aluminosilicate solid solutions (in addition to the iron produced in thermite reactions) was developed. These materials were evaluated for their strong acid resistance (pH 1), carbonate resistance (sodium carbonate) and thermal shock resistance (600 °C heating → cold water quenching repeated three times). Performance of different materials was evaluated based on the changes in mechanical properties, water-fillable porosity, phase changes under stress conditions. The aluminosilicate product exhibited very good corrosion resistance, both from material loss and strength perspectives, while the other products performed with varying degrees of stability. This paper presents the results of the thermite corrosion studies and describes the novel tools being deployed, and under development, to satisfy challenging barrier and intervention applications.

02 PETROLEUM↗