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DOE OSTI2024

The atomic-level structure and stability of interfaces of Pt nanoparticles in alumina: An experimental and computational evaluation

The atomic-level structure of interfaces between Pt and a transition form of Al2O3 were studied using a combination of electron microscopy and first principles calculations. A model system of Pt nanoprecipitates in Al2O3 were formed in sapphire wafers via high-energy ion implantation of Pt followed by thermal annealing at 1000 °C in air. The Pt nanoparticles took the form of tetrahedra and truncated tetrahedra primarily bound by {111}Pt facets. The high prevalence of these facets motivated the development of density functional theory (DFT) based models of (111)Pt interfaces with six different chemical terminations of ( 2 ¯ 01 ) θ-alumina. The atomic-level structure of the Pt/Al2O3 interfaces was characterized with aberration-corrected scanning transmission electron microscopy (STEM) and the experimental images were compared to STEM image simulations of the DFT models. The model interface with Pt bonded to oxygen-terminated θ-Al2O3, with the Pt located on top of the O and with an underlying layer of octahedral Al, provided the best match to the experimental images. This interfacial termination is also the most stable for the thermal annealing conditions used based on thermodynamic calculations of the interfacial energy as a function of temperature and oxygen partial pressure. This experimentally verified model provides a basis for improving models of Pt/γ-alumina interfaces.

Clauser, A L↗

DOE OSTI2026

Low-Temperature Pyrolysis of Aliphatic Polymers Using a Fluorinated Amorphous Silica–Alumina: Cooperative Reactivity between a Redox-Active Radical and an Aluminum Lewis Site

Fluorinated amorphous silica–alumina (F-ASA) prepared by the thermolysis of Krossing’s Al(OC(CF 3 ) 3 ) 3 (PhF) Lewis superacid supported on silica is a very reactive catalyst that promotes the pyrolysis (cracking) of aliphatic polymer melts to produce low molecular weight hyperbranched oils. Initial spectroscopic studies reported previously (Gao, J.; Perras, F. A.; Conley, M. P. J. Am. Chem. Soc . 2025 , 147, 18145–18154) showed that this material contains a distribution of four-, five-, and six-coordinate aluminum sites and a small amount of Brønsted acid sites, similar to typical amorphous silica–alumina materials that are far less reactive in the pyrolysis of aliphatic polymer melts. The objective of this study was to determine whether other active sites present in F-ASA could facilitate pyrolysis reactions. This study provides evidence for the presence of a redox-active silicon oxycarbide persistent radical ((≡Si) 3 C•) in F-ASA. Mims ENDOR EPR experiments show that (≡Si) 3 C• is located close to aluminum. Contacting F-ASA with thianthrene (Th) results in oxidation to form the [Th •+ ][F–ASA] ion-pair, while reactions with 1-hydroxy-2,2,6,6-tetramethylpiperidine (TEMPOH) result in H atom transfer to form TEMPO radical and F-ASA-H containing a mildly acidic (≡Si) 3 C–H. Poisoning studies show that both Lewis acidity and (≡Si) 3 C• are required for polymer pyrolysis reactivity. Finally, we propose that F-ASA promotes the formation of alkyl radicals in polymer melts, which are key intermediates in the thermal pyrolysis reactions of aliphatic polymers, involving the cooperative reactivity of both the Lewis acid and (≡Si) 3 C•.

aluminum↗

DOE OSTI2021

Machine learning-based microstructure prediction during laser sintering of alumina

Abstract Predicting material’s microstructure under new processing conditions is essential in advanced manufacturing and materials science. This is because the material’s microstructure hugely influences the material’s properties. We demonstrate an elegant machine learning algorithm that faithfully predicts the microstructure under new conditions, without the need of knowing the governing laws. We name this algorithm, RCWGAN-GP, which is regression-based conditional generative adversarial networks with Wasserstein loss function and gradient penalty. This algorithm was trained with experimental SEM micrographs from laser-sintered alumina under various laser powers. The RCWGAN-GP realistically regenerates the SEM micrographs under the trained laser powers. Impressively, it also faithfully predicts the alumina’s microstructure under unexplored laser powers. The predicted microstructure features, including the morphology of the sintered particles and the pores, match the experimental SEM micrographs very well. We further quantitatively examined the prediction accuracy of the RCWGAN-GP. We trained the algorithm with computer-created micrograph datasets of secondary-phase growth governed by the well-known Johnson–Mehl–Avrami (JMA) equation. The RCWGAN-GP accurately regenerates the micrographs at the trained time series, in terms of the grains’ shapes, sizes, and spatial distributions. More importantly, the predicted secondary phase fraction accurately follows the JMA curve.

08 HYDROGEN↗

DOE OSTI2021

Ultrathin alumina passivation for improved photoelectrochemical water oxidation catalysis of tin oxide sensitized by a phosphonate-functionalized perylene diimide first without, and then with, CoOy

Previously, a photoanode composed of nanostructured SnO 2 coated with the perylene diimide dye N,N'-bis(phosphonomethyl)-3,4,9,10-perylenediimide (PMPDI) plus photoelectrochemically deposited cobalt oxide (CoO y ) was shown to photoelectrochemically oxidize water at 31 ± 7% faradaic efficiency. A non-ideal part of that prior system is that the addition of the known CoO y water oxidation catalyst (WOC) resulted in a reduction of the total photocurrent rather than the anticipated increase, due to an increase in charge-carrier recombination. Herein, we show deposition of an ultrathin alumina overlayer applied by atomic layer deposition (ALD) on the SnO 2 /PMPDI photoanode can improve the photoactivity and catalytic activity of the system; the addition a ca. 1 nm-thick AlO x layer deposited on a 4000 nm (i.e., 4 micron) thick mesoporous anode system can and does have a positive, 2.5-fold improvement in the steady-state photocurrent with 29 ± 9% faradaic efficiency vs. the control anode without alumina passivation by reducing charge-carrier recombination. Moreover, ALD-deposited AlO x layer does help support the understanding of the “anti-catalysis” of co-depositing a CoO y WOC on the SnO 2 /PMPDI DS-PECs—specifically the picture of direct CoO y –SnO 2 contact-mediated recombination—but that AlO x layer was unable to improve the photocurrent in a net SnO 2 /PMPDI/AlO x (/CoO y ) system. We attribute the lack of a performance enhancement by CoOy WOC to incomplete coverage of each SnO 2 nanoparticle by the AlO x . Overall, we find the addition of an optimized ultrathin AlOx layer (0.6 nm thick; deposited at 85 °C) improves the SnO 2 /PMPDI/AlO x system's photoactivity by a factor of up to ca. 3-fold with reduced recombination. These results document that metal-oxide passivation by low-temperature ALD can be an effective strategy for improving the water oxidation performance of even nanostructured dye sensitized-photoelectrochemical cell.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Are the Brønsted acid sites in amorphous silica-alumina bridging?

Competing models exist to explain the differences in the activity of zeolites and amorphous silica–aluminas. Some postulate that silica–alumina contains dilute zeolitic bridging acid sites, while others favor a pseudo-bridging silanol model. Here, we employed a selective isotope labeling strategy to assess the existence of Si–O(H)–Al bonds using NMR-based distance measurements.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Development of an atomic layer deposition system for deposition of alumina as a hydrogen permeation barrier

Tritium permeation into and through materials poses a critical challenge for the development of nuclear fusion reactors. Minimizing tritium permeation is essential for the safe and efficient use of available fuel supplies. In this work, we present the design, construction, and validation of custom atomic layer deposition (ALD) and deuterium permeation measurement systems aimed at developing thin-film hydrogen permeation barriers. Using the ALD system, we deposited conformal $\mathrm{Al}_{2}\mathrm{O}_{3}$ films on copper foil substrates and characterized their growth behavior, morphology, and composition. ALD growth rates of ∼1.1 Å/cycle were achieved for temperatures between 100 ∘ C and 210 ∘ C. Permeation measurements on bare and alumina coated copper foils revealed a significant reduction in deuterium flux with the addition of a ∼10 nm $\mathrm{Al}_{2}\mathrm{O}_{3}$ layer. While bare copper followed diffusion-limited transport consistent with Sievert’s law, the alumina-coated samples exhibited surface-limited, pore-mediated transport with linear pressure dependence. Arrhenius analysis showed distinct differences in activation energy for the two transport regimes, and permeation reduction factors exceeding an order of magnitude were observed. These results demonstrate the potential of ALD-grown $\mathrm{Al}_{2}\mathrm{O}_{3}$ films as effective hydrogen isotope barriers and provide a foundation for future studies on film optimization and integration into fusion-relevant components.

atomic layer deposition↗

DOE OSTI2025

Microstructure and bonding between calcium aluminate cement‐containing gahnite–alumina matrix and refractory aggregates

Calcium aluminate cement enhances the thermomechanical properties of refractory castables through the formation of acicular calcium hexaluminate (CaO·6Al 2 O 3 ), Ca 2 Mg 2 Al 28 O 46 (CAM-I), and CaMg 2 Al 16 O 27 (CAM-II) phases in MgO- or MgAl 2 O 4 -containing castables. The compatibility of CA 6 with gahnite (ZnAl 2 O 4 ), and acicular Ca 2 Zn 2 Al 28 O 46 (CAZ-I) and CaZn 2 Al 16 O 27 (CAZ-II) phases formation have been previously reported. Here, in this work, the interaction between a CAC binder containing ZnAl 2 O 4 -Al 2 O 3 matrix with commonly used refractory aggregates such as tabular alumina (TA), alumina-rich (AR90, AR78) and stoichiometric (SM72) MgAl 2 O 4 spinels, and fused and dead-burned magnesia (FM, DBM, respectively) were investigated at 1650°C for 5 h. Microstructural analysis, using digital microscopy, scanning electron microscopy, and energy dispersive spectroscopy, revealed the formation of acicular CaZn 0.18 Al 11.82 O 18.91 , CAZ-I and CAZ-II grains, and strong interfacial bonding between the matrix and TA and spinel aggregates. FM and DBM were found to debond from the matrix. Thick interface layers were observed between the matrix and all the aggregates but TA. Null hypothesis significance testing (NHST) shows that the difference in the number of acicular grains between the interface zone and the bulk matrix (Z) is statistically significant for AR90/Z, SM72/Z, FM/Z, and DBM/Z interfaces, but not significant for TA/Z and AR78/Z. The role of the aggregates’ chemistry on the interfacial bonding and microstructure evolution is discussed.

Ramteke, Rajat Durgesh [Univ. of Alabama, Birmingh↗

DOE OSTI2025

On the role of α-alumina in the origin of life: Surface-driven assembly of amino acids

We investigate the hypothesis that mineral/water interfaces played a crucial catalytic role in peptide formation by promoting the self-assembly of amino acids. Using classical molecular dynamics simulations, we demonstrate that the α-alumina(0001) surface exhibits an affinity of 4k B Tfor individual glycine or GG dipeptide molecules due to hydrogen bonds. In simulations with multiple glycine molecules, surface-bound glycine enhances further adsorption, leading to the formation of long chains connected by hydrogen bonds between the carboxyl and amine groups of glycine molecules. We find that the likelihood of observing chains longer than 10 glycine units increases by at least five orders of magnitude at the surface compared to the bulk. This surface-driven assembly is primarily due to local high density and alignment with the alumina surface pattern. Together, these results propose a model for how mineral surfaces can induce configuration-specific assembly of amino acids, thereby promoting condensation reactions.

Science & Technology - Other Topics↗

DOE OSTI2024

Anti-reflection coating with mullite and Duroid for large-diameter cryogenic sapphire and alumina optics

We developed a broadband two-layer anti-reflection (AR) coating for use on a sapphire half-wave plate (HWP) and an alumina infrared (IR) filter for the cosmic microwave background (CMB) polarimetry. Measuring the faint CMB B-mode signals requires maximizing the number of photons reaching the detectors and minimizing spurious polarization due to reflection with an off-axis incident angle. Sapphire and alumina have high refractive indices of 3.1 and are highly reflective without an AR coating. This paper presents the design, fabrication, quality control, and measured performance of an AR coating using thermally sprayed mullite and Duroid 5880LZ. This technology enables large optical elements with diameters of 600 mm. We also present a thermography-based nondestructive quality control technique, which is key to assuring good adhesion and preventing delamination when thermal cycling. We demonstrate the average reflectance of about 2.6% (0.9%) for two observing bands centered at 90/150 (220/280) GHz. At room temperature, the average transmittance of a 105 mm square test sample at 220/280 GHz is 83%, and it will increase to 90% at 100 K, attributed to reduced absorption losses. Therefore, our developed layering technique has proved effective for 220/280 GHz applications, particularly in addressing dielectric loss concerns. This AR coating technology has been deployed in the cryogenic HWP and IR filters of the Simons Array and the Simons observatory experiments and applies to future experiments such as CMB-S4.

Sakaguri, Kana (ORCID:0000000156678118)↗

DOE OSTI2021

Technical Note CRYOFRABR#002/2021: Activated-copper-coated alumina granules synthesis

Detailed experimental studies of oxygen capture in the argon purification process using activated-copper on alumina and layered double hydroxide (LDH) were carried out, and the results were compared to the BASF commercial copper material Cu-0226 S performance. Here, we report the following main findings: i) the desired crystal structures for the studied materials were obtained after the synthesis process, ii) the use of the LDH structure promoted greater dispersion of the CuO phase when compared to BASF commercial catalyst, iii) alumina impregnated with copper demonstrated a similar result as the BASF sample for O 2 capture, and iv) among the three samples evaluated, the LHD sample demonstrated the best results regarding oxygen capturing performance becoming a promising structure for further studies.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Atomistic Modeling of the Interphase Structure between Alumina and Al12Fe2Cr Quasicrystal Approximant

Molecular dynamics simulations are performed to study the stability of an fcc metallic interlayer phase between an iron aluminide quasicrystal approximant (QCA) phase (84.2 Al, 5.7 Fe, 5.4 Ni, and 4.7 at.% Cr) and aluminum oxides (α-Al 2 O 3 and γ-Al 2 O 3 ). The presence of the interlayer phase was experimentally observed in some regions of the inner diameter surface of a TPBAR cladding tube. The simulations employed existing many-body (MEAM and EAM) interatomic potentials to describe atomic interactions in the interlayer and QCA phases, and Buckingham+Coulomb pair interactions for the alumina and between the alumina and the QCA (or fcc). Interface systems of QCA/alumina, fec/alumina, and QCA/fcc are modeled and the fracture energy of the interfaces is calculated. Based on the fracture energies, for the γ-Al 2 O 3 , both MEAM and EAM suggest that the fcc interlayer phase would not form. For the α-Al 2 O 3 , the MEAM predicts that the fcc phase would form, however, the EAM predicts that it forms only if the α-Al 2 O 3 is Al-terminated at the interface. For the O-terminated α-Al 2 O 3 , the EAM predicts the fcc phase would not form, consistent with the results for γ-Al 2 O 3 .

36 MATERIALS SCIENCE↗

DOE OSTI2025

Parametric Optimization of Nanostructured Alumina Forming Austenitic Alloys

Alumina-forming austenitic (AFA) alloys provide excellent oxidation resistance through the formation of a stable alumina scale, but their relatively high Ni content might limit application in core structural components because of helium generation and swelling under irradiation. Increasing the density of nanoscale features in the microstructure is a promising route to improve sink strength and mitigate these effects. Conventional oxide dispersion–strengthened (ODS) steels achieve this through mechanical alloying (MA), but the approach is costly and difficult to scale. In this milestone, additive manufacturing was applied as an alternative pathway to fabricate nanostructured AFA (NAFA) alloys with dual precipitation of oxides and nitrides enabled by reactive atmosphere processing. In FY25, two compositions, NAFA-1 (AFA-05) and NAFA-2, were produced and compared. Both alloys achieved densities above 99% of theoretical values, but NAFA-2 exhibited microcracking associated with Nb-rich intermetallic formation, indicating the need for further chemistry optimization. Nitrogen and oxygen uptake was confirmed on selected builds, demonstrating the intended dual-precipitate dispersion. Mechanical testing showed that AM-processed NAFA alloys exceed conventionally produced ODS steels in high-temperature tensile strength and fracture toughness. Preliminary Cu ion irradiation results further suggest improved resistance compared to wrought austenitic alloys. While the current alloys are promising for their compatibility in high-temperature air or liquid Pb environments, modifications to composition will be required for long-term operation in high-temperature impure sodium systems. Future work will focus on refining alloy chemistry to suppress laser powder bed fusion–induced cracking and scaling production to reactor-relevant dimensions using directed energy deposition as a pathway toward net-shape cladding fabrication.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Use of Modeling and Experiments to Assess the Effect of Minor Alloying Additions on Alumina Scale Formation during High-Temperature Oxidation

During the last decades, new generations of Ni-based superalloys have emerged with judiciously controlled chemistries. These alloys heavily rely on the addition of refractory elements to enhance their mechanical properties at elevated temperatures; however, a clear interpretation of the influence of these minor-element additions on the alloy's high-temperature oxidation behavior is still not well understood, particularly from the standpoint of predicting the transition from internal to external alumina formation. In this context, the present investigation describes a systematic study that addresses the intrinsic effects that minor element additions of Nb, Ta, and Re have on the oxidation behavior of alumina-scale forming γ-Ni alloys. By combining a novel simulation approach with high-temperature oxidation experiments, the present study evidences the generally positive effect associated with 2 at. % addition of Ta and Re as well as the detrimental consequences of Nb additions on the 1100 °C oxidation of (in at. %) Ni-6Al-(0,4,6,8)Cr alloys.

Rodriguez, Rafael↗

DOE OSTI2022

Role of Cr Content in Microstructure, Creep, and Oxidation Resistance of Alumina-Forming Austenitic Alloys at 850–900 °C

Creep-rupture properties and oxidation behavior of a series of alumina-forming austenitic (AFA) alloys with variations of Cr contents, based on Fe-(13.5-18)Cr-25Ni-4Al-1.5Nb-0.1C in weight percent, have been evaluated at 850–900 °C. The study investigates material responses in the properties and microstructure through compositional modifications in AFA alloys, targeting performance optimization of alloys under high-temperature, corrosive industrial environments. The creep-rupture life of the alloys at 850 °C and 30MPa monotonically decreased with increasing Cr content, which was correlated with changes in secondary phase volume fractions, such as the reduction in B2-NiAl + Laves-Fe2Nb and increase in Sigma-FeCr with Cr content. The oxidation test at 900 °C in a water-vapor containing environment revealed a range of Cr content from 13.9 to 15.7 wt.%, enabling the formation of stable, protective external alumina scale as well as preventing internal oxidation/nitridation for up to total 7000 h exposure. On the other hand, the alloys with >16.7 wt.% Cr formed Sigma precipitates, which caused a reduction in not only Cr but also Al in the austenite matrix, resulting in less oxidation resistance than other alloys. The findings will guide the further optimization of material performance in the AFA alloy series.

36 MATERIALS SCIENCE↗

NASA NTRS1975

Exploring the cell: Sodium (beta-alumina) cupric chloride - Aluminum chloride - Sodium chloride between 136 and 200 C

Experiments were done with a molten-salt catholyte (initially CuCl2 in AlCl3-NaCl) separated from molten Na by beta alumina. The open-circuit reduction potentials were 4.3 and 3 volts for Cu++ and Cu+, respectively. High polarization and nonrechargeability characterized the cell's operation. The cell's ohmic resistance during discharge was higher than what would be expected from only the ionic resistance of the beta-alumina.

Miller, R. O.↗

NASA NTRS1982

Alumina fiber strength improvement

The effective fiber strength of alumina fibers in an aluminum composite was increased to 173,000 psi. A high temperature heat treatment, combined with a glassy carbon surface coating, was used to prevent degradation and improve fiber tensile strength. Attempts to achieve chemical strengthening of the alumina fiber by chromium oxide and boron oxide coatings proved unsuccessful. A major problem encountered on the program was the low and inconsistent strength of the Dupont Fiber FP used for the investigation.

Pepper, R. T.↗

NASA NTRS1982

Study of alumina-trichite reinforcement of a nickel-based matric by means of powder metallurgy

Research was conducted on reinforcing nickel based matrices with alumina trichites by using powder metallurgy. Alumina trichites previously coated with nickel are magnetically aligned. The felt obtained is then sintered under a light pressure at a temperature just below the melting point of nickel. The halogenated atmosphere technique makes it possible to incorporate a large number of additive elements such as chromium, titanium, zirconium, tantalum, niobium, aluminum, etc. It does not appear that going from laboratory scale to a semi-industrial scale in production would create any major problems.

Walder, A.↗

NASA NTRS1983

Viscous flow behavior of four iron-containing silicates with alumina, effects of composition and oxidation condition

The viscosity of a magma is an important parameter in connection with its effect on geologic processes such as melt segregation, magma vesiculation, and crystal fractionation. Though most models of geologic processes assume relatively low values for the magma viscosity less than 10,000 poise, it would be useful to have an empirical model for estimating viscosities when the process occurs during continuous cooling to a temperature region where the viscosity is expected to be very high. The considered work has been carried out to provide the experimental measurements of viscosity at low temperatures which would be used in formulating the empirical model. Ten iron-containing silicate compositions have been investigated by Klein et al. (1981), and four of these compositions have been selected for the present study with alumina. The study involves substitutions of Al2O3 for FeOx at Na2O/Al2O3 moles greater than one. For the four iron-containing silicate glasses with alumina, the viscosity at a given temperature is found to increase with increasing (Fe + Al).

Klein, L. C.↗