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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 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
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↗
NASA NTRS1973

Carbon microsphere-filled Pyrrone foams.

Syntactic foam formulations were prepared from mixtures of Pyrrone prepolymers and hollow carbon microspheres. Very low curing shrinkages were obtained for high volume loadings of microspheres. The resulting syntactic foams were found to be remarkably stable over a wide range in temperature. A technique was developed for the emplacement of these foam formulations in polyimide-fiberglass, titanium alloy and stainless steel honeycomb without sacrificing low curing shrinkage or thermal stability.

Kimmel, B. G.↗
DOE OSTI2025

Tailoring composition and deformation modes at the microstructural level for next generation low-cost high-strength austenitic stainless steels

The objective of this project is to enable deliberate development of cost-effective, hydrogen resistant alloys by establishing detailed relationships specific to the effects of alloy composition, short-range order (SRO), and microsegregation in the presence of hydrogen on the transition between homogeneous deformation and localized plasticity in shear bands. In collaboration with the International Institute for Carbon-Neutral Energy Research, I2CNER, at Kyushu University in Japan, we conceptualized, designed, and manufactured four austenitic alloys that maintain corrosion resistance and ensure lower cost relative to baseline commercial alloys. The mechanical properties and deformation modes of the novel alloys (KU alloys) were assessed in the presence of hydrogen (H). Correlations between composition and performance revealed that two of the KU alloys are suitable replacements for 316 steel, while another is a viable replacement for 304 steel at room temperature. We found that, in the presence of other austenite stabilizing elements namely Mn and N, replacing Ni with Cu does not lead to martensite formation as has been previously reported.1–3 Furthermore, we found that the addition of Cu leads to an earlier onset of multiple slip resulting in an relative earlier onset of a higher work hardening rate (WHR). Greater understanding of the relationships between alloy composition and SRO required the development of a novel advanced electron diffraction methodology to characterize SRO in complex FCC alloys. This innovative approach, which combines fluctuation and correlation analyses of diffuse-scattering signals, successfully differentiated between SRO and long-range ordering (LRO). Further investigations into annealed austenitic stainless steels could provide insights into manipulating SRO and its effects on material properties. Atomistic simulations provided understanding of SRO behavior that was difficult to capture experimentally. This project created the first spin cluster expansion model that is able to capture and describe SRO effects in Fe-Ni-Cr FCC alloys, accounting for the non-negligible effects of magnetism. An automated computational workflow was established to provide reliable predictions of SRO in Fe-Ni-Cr austenitic alloys, both with and without the presence of H atoms. Analysis of the propensity for SRO in Fe-Ni-Cr alloys revealed that H tends to cluster with specific, well-defined SRO domains. The computational framework is general purpose and can be extended to realistic stainless steels across diverse composition ranges. With confidence that SRO is possible in austenitic stainless steels, we developed a discrete dislocation finite element code to understand the interaction of dislocations with SRO in the presence of H. By incorporating H effects on the dislocation emission and SRO stress field we show that the critical stress for the dislocation pileup to breakthrough the SRO domain decreases in the presence of H, which directly contributes localized deformation at the macroscale. Through the simulation of a uniaxial tension test, we demonstrated that H-induced weakening of SRO stress field and H-enhanced dislocation emission can lead to the onset of shear localization at lower macroscopic strains. As a whole, this project identified three novel alloys that show improvements in performance and cost efficiency for H-facing applications by studying correlations between alloy chemistry and deformation behavior. We also made significant advancements to experimental and computational methodologies necessary to study the chemistry and distribution of SRO across a range of alloys, which in turn allowed us to demonstrate how deformation mechanisms change due to the contributions of SRO in austenitic alloys in the presence of H. The combined advancements in fundamental understanding with novel alloy development in this project has increased the viability of next generation H-technologies for the broader public through accessible low-cost alloys and accelerated development towards future H-infrastructure.

08 HYDROGEN↗
NASA NTRS1974

Vacuum thermal-mechanical fatigue testing of two iron base high temperature alloys

Ultrahigh vacuum elevated temperature low cycle fatigue and thermal fatigue tests of 304 stainless steel and A-286 alloy have shown significant effects of frequency and combined temperature-strain cycling on fatigue life. At constant temperature, the cyclic life of both alloys was lower at lower frequencies. Combined temperature-strain cycling reduced fatigue life with respect to isothermal life at the maximum temperature of the thermal cycle. Life reductions with in-phase thermal cycling (tension at high temperature, compression at low temperature) were attributed to grain boundary cavitation caused by unreversed tensile grain boundary sliding. The proposed mechanism for out-of-phase cavity generation involved accumulation of unreversed compressive grain boundary displacements which could not be geometrically accomodated by intragranular deformation in the low-ductility A-286 alloy.

Sheffler, K. D.↗
NASA NTRS1992

On bilinearity of Manson-Coffin low-cycle-fatigue relationship

Some alloy systems, such as aluminum-lithium alloys and dual-phase steels, have been found to show a bilinear Manson-Coffin low-cycle-fatigue relationship. This paper shows that such bilinear behavior is related to the cyclic stress-strain curve. A bilinear cyclic stress-strain curve is a likely indication of a bilinear Manson-Coffin relationship. It is shown that materials other than aluminum-lithium alloys and dual-phase steels also may exhibit bilinear Manson-Coffin behavior. Implications for design are discussed.

Radhakrishnan, V. M.↗
DOE OSTI2022

ZnCr and ZnNb Cold Spray Coatings

Novel cold spray zinc-based alloy coatings have been investigated for corrosion protection of API 5L low carbon steel pipelines used in transporting natural gas. These different zinc alloy coatings are designed for use to help prevent internal corrosion and improve the lifespan of steel pipelines via sacrificial anodic protection. The corrosion behavior of these cold deposited zinc alloy coatings was investigated in CO2 saturated 3.5 wt.% NaCl solutions under simulated natural gas pipeline conditions. Electrochemical tests were conducted at 25 and 40 °C to determine the polarization resistance and galvanic current between each coating and the steel substrate in the galvanic couple. Tests were conducted at atmospheric, 1 bar, pressure. The results indicate that use of these coatings has the potential to increase the lifespan of steel pipelines above what a zinc coating alone could provide.

Teeter, Lucas↗
NASA NTRS1984

Aircraft landing dynamics facility carriage weld test program

A welded tubular structure constructed of low alloy high strength quenched and tempered steel was tested. The consistency of the mechanical strengths and chemical composition and the degree of difficulty of obtaining full strength welds with these steels is characterized. The results of constructing and testing two typical connections which are used in the structure design are reported.

Lawson, A. G.↗
NASA NTRS2001

Corrosion of Stainless-Steel Tubing in a Spacecraft Launch Environment

This is a report of exposure of various metal tubing to oceanfront launch environments. The objective is to examine various types of corrosion-resistant tubing for Space Shuttle launch sites. The metals were stainless steels (austenitic, low-carbon, Mo-alloy, superaustenitic, duplex, and superferritic), Ni-Cr-Mo alloy, Ni-Mo-Cr-Fe-W alloy, and austenitic Ni-base superalloy.

Barile, Ronald G.↗
DOE OSTI2023

Decoupling the effects of texture and composition on magnetic properties of Fe-Si sheet processed by shear deformation

Soft magnetic Fe-Si alloys (electrical steels) possess exceptional functional properties such as high permeability, low coercivity, and low core loss, which generally improve with increasing Si content in the alloy. However, Fe-Si alloys containing > 3.5 wt% Si are also characterized by prohibitively low workability and poor ductility that have prevented their efficient commercial production in sheet form by rolling. This has limited their use for improving efficiency of motors and transformers. In this study, hybrid cutting-extrusion (HCE) is used as a single-step thermomechanical processing method to produce continuous Fe-Si alloy sheet with high Si compositions of 4 wt% to 6.5 wt%. HCE sheet is shown to have a homogeneous annealed grain structure and simple-shear crystallographic textures. By controlling the HCE deformation path, varied crystallographic shear textures are created in the sheet. Quasi-static magnetic properties of the HCE sheet are evaluated to decouple the effects of sheet texture and Si composition on resultant permeability and coercivity properties. The results suggest that HCE, with suitable process scaling, is a viable route for production of high-Si content electrical steel sheet for next-generation motors and transformers.

36 MATERIALS SCIENCE↗
DOE OSTI2022

UK-US Collaboration on Fossil Energy R&D: Steam Side Oxidation

In recent years, interest in increasing the efficiency of power plants based on steam generation has led to the need to develop and qualify materials capable of operating at steam temperatures and pressures significantly higher than those employed in current power plants. The overall focus of this international program is on using ferritic-martensitic steels to the maximum possible temperature, before switching to austenitic steels and/or Ni-based alloys. The relatively low Cr content of these alloys raises concerns regarding their resistance to steam oxidation at these higher temperatures. Earlier work in this collaboration addressed the reliability of data from atmospheric pressure, laboratory-based steam oxidation tests. This raised issues regarding how representative the laboratory-grown oxides were compared to those formed on service-exposed material and how the tests could be made more reliable by introducing added complexity. In general laboratory-scale exposures are conducted under isothermal conditions at ambient or slightly elevated pressure, using a relatively low flow rate of steam. The coupons used in these tests are normally flat cuboids which have been ground to homogenise the surface and remove any pre-existing features. However, there is a concern that these samples and exposures are not representative of service conditions, and so it is necessary to quantify the influence of transient conditions, such as heat flux, pressure and sample geometry/surface conditions. To address such concerns a new collaborative program of work was initiated to determine the influence of these added features on oxidation kinetics and oxide scale morphology. The overall aim was to improve the understanding of alloy performance in ultrasupercritical (USC) steam conditions and qualify suitable test procedures.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2025

Improved creep performance of CoCrFeNi high entropy alloys by Mo addition

The CoCrFeNi family of high entropy alloys has good mechanical and corrosion properties, performing like stainless steels with low yield stresses. They could, however, benefit from hardening methods for structural and high temperature applications. Here, this work investigates the potential for the CoCrFeNi alloy to be hardened with the addition of Mo. A series of CoCrFeNiMo alloys and their CoCrFeNi counterparts were subsequently manufactured at NETL and then mechanically creep tested at 650°C. The alloys were designed to possess a range of stacking fault energies which influence the mechanical properties of the alloys via the motion of their dislocations under stress. Results show that Mo-containing variants have creep rupture lives ranging from 4000 to 8000 hours, i.e., about two orders of magnitude longer than those for Mo-free variants. The significantly improved creep performance of the Mo-containing alloys is due to a combination of solid solution strengthening and precipitation strengthening from µ-phase and carbides.

36 MATERIALS SCIENCE↗
NASA NTRS1972

Investigation of the plastic fracture of high strength steels

An investigation of the plastic fracture process to improve tensile strength in high strength steels is presented. Two generic types of steels are considered: a quenched and tempered grade and a maraging grade, in order to compare two different matrix microstructures. Each type of steel was studied in commercial grade purity and in special melted high purity form, low in residual and impurity elements. The specific alloys dealt with include AISI 4340 and 18 Ni, 200 grade maraging steel, both heat treated to the same yield strength level of approximately 200 ksi.

Cox, T. B.↗
DOE OSTI2025

Mechanical Property Measurements of HFIR-irradiated FM and ODS Alloys

This report provides a summary of the post-irradiation examination of the tensile properties of three ODS ferritic alloys, 14YWT-SM13, 9YWTV-PM2 and OFRAC, and two HT9 ferritic/martensitic steels, one with low N content and the other with high N content. The neutron irradiations were conducted in the flux trap of the High Flux Isotope Reactor as part of the Additive Manufacturing, Oxide Dispersion Strengthened Alloys and Wrought Steels (AMOW) irradiation campaign. Sub-sized tensile specimens fabricated from each material were exposed to nominal target temperatures and neutron doses of 300°C, 385°C, and 525°C and 8 dpa, 16 dpa, and 50 dpa, respectively.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Mechanical Property Measurements of HFIR-irradiated FM and ODS Alloys

This report provides a summary of the post-irradiation examination of the tensile properties of three ODS ferritic alloys, 14YWT-SM13, 9YWTV-PM2 and OFRAC, and two HT9 ferritic/martensitic steels, one with low N content and the other with high N content. The neutron irradiations were conducted in the flux trap of the High Flux Isotope Reactor as part of the A dditive M anufacturing, O xide Dispersion Strengthened Alloys and W rought Steels (AMOW) irradiation campaign. Sub-sized tensile specimens fabricated from each material were exposed to nominal target temperatures and neutron doses of 300°C, 385°C, and 525°C and 8 dpa, 16 dpa, and 50 dpa, respectively.

14YWT-SM13, 9YWTV-PM2, and OFRAC, and two HT9 ferr↗