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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Corrosion-Resistant Coatings on Spent Nuclear Fuel Canisters to Mitigate and Repair Potential Stress Corrosion Cracking (FY23 Status)

This report summarizes the activities performed by Sandia National Laboratories in FY23 to identify and test coating materials for the prevention, mitigation, and/or repair of potential chloride-induced stress corrosion cracking in spent nuclear fuel dry storage canisters. This work continues efforts by Sandia National Laboratories that are summarized in previous reports from FY20 through FY22 on the same topic. In FY23, Sandia National Laboratories, in collaboration with five industry partners through a memorandum of understanding, evaluated the physical, mechanical, and corrosion-resistance properties of eight different coating systems. The evaluation included thermal and radiation environments relevant to various time periods of storage for spent nuclear fuel canisters. The coating systems include polymeric (polyetherketoneketone, modified polyimide/polyurea, modified phenolic resin, epoxy), organic/inorganic ceramic hybrids (silane-based polyurethane hybrid and a quasi-ceramic sol-gel polyurethane hybrid), and coatings utilizing a Zn-rich primer applied to stainless steel coupons. The results and implications of these tests are summarized in this report. These analyses will be used to identify the most effective coatings for potential use on spent nuclear fuel dry storage canisters and to identify specific needs for further optimization of coating technologies for application on spent nuclear fuel canisters.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Cold Spray Deposition of 304L Stainless Steel to Mitigate Chloride-Induced Stress Corrosion Cracking in Canisters for Used Nuclear Fuel Storage

A feasibility study of the cold spray deposition process of 304L stainless steel on 304L stainless steel substrates as a mitigation method for chloride-induced stress corrosion cracking (CISCC) has been investigated under various substrate conditions. The study is aimed at the application of this technology to mitigate CISCC that may potentially occur in or nearthe fusion welded regions of stainless steel canisters in Dry Cask Storage System (DCSS) for used nuclear fuels. Spherical gas-atomized 304L stainless steel powder, in the size range of 25 µm to 44 µm, was used as a feedstock powder for the cold spray process. The powder was deposited on four types of 304L substrates with various surface conditions: as-polished, oxidized, cold-rolled, plates with prototypical CISCC. The effects of cold spray parameters on quality of cold spray coatings were investigated. Thickness, porosity, and phases in the as-deposited materials were evaluated using scanning electron microscopy (SEM) and X-ray diffraction (XRD), and correlated with microhardness and adhesion strength measured via micro-indentation and ASTM C633 pulling test, respectively. XRD analysis of the coatings was also conducted to examine the effects of cold spray condition on residual stress state in the coating. Detailed cross-sectional examination of coating/substrate interfaces was performed with transmission electron microscopy (TEM) equipped with energy dispersive spectroscopy (EDS). Dense and continuous coatings with good adhesion strength and hardness were produced for the various substrate conditions by adjusting cold spray parameters. The results demonstrate that cold spray stainless steel coating is a viable option to provide a physical barrier against CISCC in fusion weld regions of stainless steel in corrosive chloride salt-bearing environments.

Dry Cask Storage Systems, cold spray, 304L stainle↗
DOE OSTI2026

Determining Drying Conditions to Mitigate Hanford Double Shell Storage Tank Underside Corrosion — Phase 1

The Hanford Site in Washington State has legacy radiological waste that is being retrieved from single shell tanks (SSTs) and transferred to newer, double shell tanks (DSTs) for eventual closure of the SSTs. The waste is maintained in the DSTs until eventual immobilization can be performed at the Waste Treatment and Immobilization Plant (WTP), currently under construction. Until full immobilization is complete, extended service of the DSTs must be ensured by mitigating corrosion of the steel tank walls and buried steel pipelines. A Pit Air Supply System has been developed to mitigate corrosion of the leak detection pits connected to the concrete foundations of the DSTs. The objectives for the present study are: (i) to corrode steel specimens in an electrolytic simulant to form artificial pits with specific pit depths, and (ii) to determine the temperature and humidity levels that will mitigate further pit growth. Experimental work and results will be presented to evaluate conditions associated with the PASS system and predict corrosion rates when the PASS is operating.

Atmospheric Corrosion↗
DOE OSTI2022

Laser Surface Processing of Alloys for Corrosion Protection (Final Project Report of Marine Energy Seedling Project)

This is the final project report for the MHK Seedling project. The report describes use of laser surface processing (LSP) to modify the surface of test materials (Al, steel) and the corrosion testing performed on the resulting samples in different corrosion environments. Data shows that LSP improved the corrosion resistance of Al and steel used in this work relative to respective non-LSP samples. The data also showed that each material had a specific range of laser processing conditions where the beneficial effects of LSP (i.e. improvement in corrosion protection) were observed. Application of LSP to enable low-cost materials in marine environments, additional microstructural analysis and long-term testing are proposed to further develop this technology for marine renewable energy and systems.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Durable and Low-Cost Fractal Structured Multifunctional Coatings for Next-Generation CSP

Fractal coatings on various low-cost and high-temperature metallic substrates such as SS316, SS347, In800H, In740H, In625, Haynes 230, etc. were fabricated employing our patented novel electrodeposition process at various deposition potentials and deposition times, as well as chemical etching. The best combination of the materials and processing conditions were co-optimized for the reliable and repeatable fabrication of the multifunctional coatings. Surface morphologies were examined using SEM and AFM, and fractal characterization was done using a 3D optical surface profiler. Fractal dimension was used to identify successful fabrication and material parameters. The mechanical durability of the coatings was evaluated using several standardized tests, such as sand abrasion (ASTM D968) and adhesion (ASTM D3359), to fully characterize and demonstrate the mechanical durability of the fabricated surfaces. HTF immersion tests on the fractal multifunctional coatings were conducted based on a modification of the ASTM D870, which is established for static water immersion testing. To calculate the corrosion rates and descaled weight loss of the samples subjected to thermal exposure for different time durations (100 h, 300 h, 500 h, and optionally 750 h) to estimate the corrosion rate. While protecting the substrates from corrosion is an important goal, an allied goals is also to examine the post-corrosion temperature stability and properties of the molten salts themselves due to the dissolution of the constituents of the alloys and the corrosion products from the coatings that cause “fouling” of the molten salts. Fouling characteristics of the different molten salt HTFs exposed to coated and uncoated substrates were investigated. Finally, considering a prototype molten salt/sCO2 heat exchanger, cost/performance model is developed to demonstrate that the coatings on low-cost alloys such as stainless steel provide lower levelized cost of heat exchanger compared to high nickel content Ha230.

14 SOLAR ENERGY↗
DOE OSTI2024

Feasibility Study for Cathodic Protection of Waste Tanks at Hanford

The Hanford Nuclear Reservation site contains approximately 211 million liters of radioactive and chemically hazardous waste arising from nuclear weapons production, beginning with World War II, and continuing through the Cold War. The waste is stored in 177 carbon-steel underground storage tanks, of which 149 are single-shell tanks (SSTs) and the remaining are double-shell tanks (DSTs). The mission of an ongoing River Protection Project is to retrieve the waste from the underground storage tanks and then treat and immobilize (i.e., vitrify) it for disposal. Waste from the older SSTs is being progressively retrieved into the newer DSTs for storage pending treatment, immobilization, and disposal. Waste chemistry controls are in place to mitigate general corrosion, pitting corrosion, and stress corrosion cracking (SCC) and minimize corrosion risks to the carbon steel tank liners of DST at the Hanford Site. The chemistry control program focuses on preserving liner integrity while balancing the need for caustic/nitrite additions that have large downstream impacts on vitrification. Some of the DSTs store salt cake or sludge waste layers contain out-of-specification interstitial liquids that contact the primary tank bottom or sidewall. Remediation of such layers through chemical additions is not practical. At the present time, the most significant leak integrity concern at Hanford is for corrosion of the tank bottoms of DSTs where the solids layer is out of specification because of hydroxide ion depletion and consequently, pH values that are less than 12. Cathodic protection (CP) has been proposed as a possible way to protect the liners of such tanks against corrosion. The objective of this project was to investigate the feasibility of applying CP to Hanford DSTs to mitigate internal corrosion of the carbon steel tank primary liners. The scope of the project included (1) a literature review on the application of CP to storage tank systems, in general, and to waste tanks at the Savannah River Site (SRS) and Hanford, (2) a review of the finite element analysis (FEA) model recently developed to evaluate potentials for a DST, and (3) the development of a boundary element analysis (BEA) model for CP for a DST. Tank AN-107, one of the Hanford DSTs, was selected for this work because (1) the bottommost waste layer in the tank is out-of-specification, and (2) electrochemical and resistivity data, based on recent waste sampling and testing, are available for this tank. The overarching conclusion of this study is that, based on the available information, it is feasible to apply CP to mitigate internal corrosion of the primary liners of the Hanford DSTs. However, significant additional information and work are required before a CP system can be designed. Recommendations for next steps in the design of the CP system will be presented.

WIERSMA, BRUCE↗
DOE OSTI2020

Corrosion-Resistant Coatings for Mitigation and Repair of Spent Nuclear Fuel Dry Storage Canisters

This report summarizes the results of a literature survey on coatings and surface treatments that are used to provide corrosion protection for exposed metal surfaces. The coatings are discussed in the context of being used on stainless steel spent nuclear fuel (SNF) dry storage canisters for potential prevention or repair of corrosion and stress corrosion cracking. The report summarizes the properties of different coating classes, including the mechanisms of protection, their physical properties, and modes of degradation (thermal, chemical, radiological). Also discussed are the current standard technologies for application of the coatings, including necessary surface pretreatments (degreasing, rust removal, grinding) and their effects on coating adhesion and performance. The coatings are also classified according their possible use for in situ repair; ex situ repair, requiring removal from the overpack; and ex situ prevention, or application prior to fuel loading to provide corrosion protection over the lifetime of the canister.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Integrity Monitoring and Assessment, Prediction, Repair, and Corrosion Control of the Hanford Storage Tanks — 25213

BACKGROUND AND PROJECT TASKS Proposed work addresses focus area 1: Waste Retrieval, Transport and Closure, with particular focus on increasing volume available for tank storage 1) Refurbish/fortify existing double shell storage tanks (Tank Refurbish – Polymer Grout) 2) Robust monitoring tools for internal corrosion (Integrity Monitoring -Reference Electrodes) 3) Mitigate external corrosion (Degradation Prevention - Cathodic Protection) 4) Determine viability of constructing new tanks, and storage room creation by way of evaporation (Cost Benefit Analysis)

Shukla, Pavan K. [Savannah River National Laborato↗
DOE OSTI2025

Determining Drying Conditions to Mitigate Hanford Transfer Line Corrosion

Hanford Site Background • Hanford site located in Washington State and established in 1943: 1460 km2 • Since 1988 the site has been engaged in a comprehensive environmental clean-up effort. Waste Tanks • 177 underground tanks with 56 million gallons of high-level radioactive waste and chemical waste in 150 Single Shell Tanks (SSTs) and 27 Double Shell Tanks (DSTs)

Shukla, Pavan K. [Savannah River National Laborato↗
DOE OSTI2020

Long-Term Corrosion Studies Of Pine Derived Bio-Oil And Blends With Heavy Fuel Oil

Biomass derived liquid fuels offer a means to reduce greenhouse gas emissions compared to those produced by combustion of petroleum derived liquid fuels. However, the corrosivity of bio-oils toward the less expensive structural materials creates a material selection problem for designers of storage tanks and combustion systems. Samples of candidate structural materials are being exposed for thousands of hours in multiple fast pyrolysis bio-oils and conditions to evaluate the corrosion resistance of these materials. One method to mitigate the corrosivity of bio-oils and speed their adoption, while also decreasing the pollution issues associated with low quality petroleum derived fuels, is to utilize blends of bio-oil and heavy fuel oil in engines currently solely burning a petroleum-based fuel. In addition to the corrosion studies conducted in 100% bio-oil, studies were also conducted with blends of the fast pyrolysis bio-oil produced from pine tree components with a heavy fuel oil that is used in ocean-going ships. This bio-oil had a very high carboxylic acid content which made it very corrosive to carbon and 2¼ Cr-1 Mo steel and even 409 stainless steel. The heavy fuel oil was not corrosive to carbon steel, but its sulfur content makes it a significant pollution producer and particularly undesirable for use near coastlines. Corrosion tests were conducted with the individual components and with various blends of the two liquid fuels. Studies showed a significantly lower corrosivity of the blends than would be projected assuming linear mixing behavior. Adoption of such blends holds the potential to reduce production of sulfur-containing exhaust gases as well as carbon dioxide from non-renewable fuels.

Keiser, Jim↗
DOE OSTI2020

Long-Term Corrosion Studies of Pine Derived Bio-Oil and Blends with Heavy Fuel Oil

Biomass derived liquid fuels offer a means to reduce greenhouse gas emissions compared to those produced by combustion of petroleum derived liquid fuels. However, the corrosivity of bio-oils toward the less expensive structural materials creates a material selection problem for designers of storage tanks and combustion systems. Samples of candidate structural materials are being exposed for thousands of hours in multiple fast pyrolysis bio-oils and conditions to evaluate the corrosion resistance of these materials. One method to mitigate the corrosivity of bio-oils and speed their adoption, while also decreasing the pollution issues associated with low quality petroleum derived fuels, is to utilize blends of bio-oil and heavy fuel oil in engines currently solely burning a petroleum-based fuel. In addition to the corrosion studies conducted in 100% bio-oil, studies were also conducted with blends of the fast pyrolysis bio-oil produced from pine tree components with a heavy fuel oil that is used in ocean-going ships. This bio-oil had a very high carboxylic acid content which made it very corrosive to carbon and 2¼ Cr-1 Mo steel and even 409 stainless steel. The heavy fuel oil was not corrosive to carbon steel, but its sulfur content makes it a significant pollution producer and particularly undesirable for use near coastlines. Corrosion tests were conducted with the individual components and with various blends of the two liquid fuels. Studies showed a significantly lower corrosivity of the blends than would be projected assuming linear mixing behavior. Adoption of such blends holds the potential to reduce production of sulfur-containing exhaust gases as well as carbon dioxide from non-renewable fuels.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2025

Determining Drying Conditions to Mitigate Hanford Transfer Line Corrosion

Radioactive waste is stored in underground, carbon-steel double-shell tanks at the Department of Energy Hanford site.1,2,3 The underground transfer lines are used to transfer the waste between the tanks and other assets at the Hanford tank farm facilities. The transfer lines constructed before 1990 are pipe-in-pipe design with most of the lines having carbon steel carrier pipe and carbon steel encasements. The lines constructed after 1990 have a stainless-steel carrier with a carbon steel encasement. The carrier lines, which are in contact with the waste, provide a critical confinement function, while the encasements provide secondary containment to reduce the risk of a release and contamination to the environment. In 2022, a visual inspection of the annulus between the encasement and the carrier for one of the pre-1990 transfer lines revealed standing liquid in contact with the carrier pipe. Additionally, a significant build-up of corrosion products on the exterior of the carrier pipe and the interior of the encasement pipe was observed. To assess the extent of condition, borescope inspections were performed in the encasement space of additional transfer lines in the facility to provide a baseline. The inspection revealed that of the lines inspected, 29 had either moisture present or evidence that moisture had been present in the past (e.g., waterline corrosion where the pipe had been exposed to standing water). Additional inspections indicated several instances of pitting corrosion on the interior of the encasement and exterior the carrier transfer lines. An image of the carrier pipe with several pits is presented in Figure 1(a) and the profiled image of the transfer line section along with the pit depths are presented Figure 1(b). As seen in the figure, the deepest pit was 73 mils on the pipe section. These lines were designated as “do-not-use” until further compensatory actions are implemented to return the lines to service.

Shukla, Pavan K. [Savannah River National Laborato↗
DOE OSTI2020

Experimental evaluation of direct current magnetron sputtered and high-power impulse magnetron sputtered Cr coatings on SiC for light water reactor applications

Two types of physical vapor deposition Cr coatings were deposited on chemical vapor deposited SiC coupons using conventional direct current magnetron sputtering (DCMS) and high-power impulse magnetron sputtering (HiPIMS) to mitigate the corrosion of SiC, an advanced fuel and structural material in light water nuclear reactor cores. Coating microstructure was characterized using scanning electron microscopy and scanning transmission election microscopy. X-ray diffraction analysis was conducted for phase identification and qualitative analysis of residual stresses. The mechanical integrity of the coatings was evaluated using scratch testing, micro-indentation, and nano-indentation tests. Additionally, the microstructure of the DCMS coating consisted of fine columnar grains with nanoscale intercolumnar channels, while the HiPIMS microstructure was denser and free of any columnar defects. The DCMS coating showed a small tensile residual stress, while the HiPIMS coating was under compressive stress. Both types of coatings showed good mechanical integrity in terms of ductility and adhesion to the substrate. Corrosion performance of the coatings was assessed with a 30-day high temperature water autoclave test. Both types of coatings formed a protective Cr 2 O 3 surface layer 20-30 nm thick during the autoclave test. In the DCMS coating, the columnar defects provided permeation pathways for water penetration resulting in oxide formation in the intercolumnar regions in the interior of the coating. Overall, both types of Cr coatings offer promise for the mitigation of hydrothermal corrosion of SiC in light water reactor operating environments.

36 MATERIALS SCIENCE↗
DOE OSTI2021

A review on molten sulfate salts induced hot corrosion

Hot corrosion has been extensively observed in various high temperature applications, which might cause large economic losses. Here, to deepen the insight and understanding of hot corrosion, we provide a detailed discussion on hot corrosion induced by molten sulfate salt, in which Na 2 SO 4 is the main chemical reactant. The hot corrosion is triggered and sustained by the negative solubility gradient of protective oxide from the oxide/salt interface to salt/gas interface. In this work, we reviewed several key factors, including temperature, gas composition, molten salt composition, alloy element and external stress, influencing the hot corrosion of alloy beneath the molten salt. The application of anti-corrosion coating seems to be the most effective and commercial mothed to mitigate hot corrosion. Therefore, the progress of the development of effective coatings, e.g., Ni-Cr coatings, aluminide coatings, silicide coatings and MCrAlY(X) coatings, has also been summarized.

36 MATERIALS SCIENCE↗
DOE OSTI2021

L-Basin Microbial Monitoring Program - Evaluation of 20 Years of Monitoring

The SRNL L-Basin corrosion surveillance and microbial monitoring programs provide early detection and characterization of corrosion attack to the fuel and storage system materials resulting from prolonged exposure to the L-Basin water environment and of changes to and impact of the diverse microbial population, respectively. The early detection of corrosion allows for adjustment of the water quality, engineering management, and fuel storage configurations to mitigate excessive corrosion attack. While microbial influenced corrosion in L-Basin has not been detected, tracking and understanding the effect of microbial populations on the stored fuel and basin water will aid in identifying remedial measures to mitigate any detrimental impact. This report reviews the microbial monitoring activities since initial characterizations in the mid-1990s.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

Corrosion protection of steel pipelines with metal-polymer composite barrier liners

Pipelines are efficient in transporting natural gas over large distances. Wet carbon dioxide present in pipelines can create an environment that is corrosive to steel. Polymer liners made from either polyethylene or polyamide (nylon) are presently used to mitigate internal corrosion in natural gas pipelines. Gas diffuses through all polymers over time, and polymer-only liners lower the steel corrosion rate by reducing the reactive gas flux to the internal surface of a pipeline. Composite liners, which incorporate one or more metallic layers that are impermeable to corrosive gases, offer better protection than polymer-only liners. In this study, we measured the methane, water vapor, and carbon dioxide permeability of a multi-layer barrier film and found it to be more effective in resisting gas permeation than polyethylene and nylon-11 films.

03 NATURAL GAS↗