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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 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Hydriding, Oxidation, and Ductility Evaluation of Cr-Coated Zircaloy-4 Tubing

Accident-tolerant fuel concepts have been developed recently in diverse research programs. Recent research has shown clear advantages of Cr-coated Zr cladding over bare cladding tubes regarding oxidation behavior under the design basis loss-of-coolant accident condition. However, limited data are available about the hydriding behavior of the Cr coating. For that purpose, Cr-coated Zricaloy-4 tubes were tested to investigate the effects of hydriding, oxidation, and postquench ductility behavior on coated Zr cladding. A high-power impulse magnetron sputtering (HiPIMS) process was used to produce a high-density coating on the Zircaloy-4 tube surface. Coated and uncoated Zircaloy-4 tube specimens underwent one-sided hydriding in a tube furnace filled with pure hydrogen gas at 425 °C. The tubing specimen ends were sealed with Swagelok plugs before the hydriding runs. For uncoated specimens, H analysis of the hydrided specimens indicated that the H content increased as the test time and initial pressure increased. However, almost no change was observed for the coated specimens that were hydrided under the same test conditions. After one-sided hydriding, the hydrided coated and uncoated specimens were exposed to steam at high temperatures for two-sided oxidation studies to simulate accident conditions. The coated specimens showed a slower oxidation: oxygen pickup was 50% lower than the uncoated specimens tested under the same conditions. Ring compression testing was performed to evaluate the embrittlement behavior of the Cr-coated specimens after hydriding and oxidation. The results indicated that the HiPIMS coating provides excellent protection from hydriding and oxidation at high temperatures.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Effect of oxidation post treatments on TiO 2 coating manufactured using reactive very low-pressure plasma spraying (R-VLPPS)

TiO 2 coatings manufactured using reactive very low-pressure plasma spraying (R-VLPPS) were analyzed in different regions related to their position compared to the plasma flame. For that, a screen was used in order to hide an area of the substrate from the direct plasma flux. The coating morphology changed from quasi lamellar structure to highly vapor structure and coatings exhibited obvious modifications in terms of phases and mechanical properties. The effect of oxidation post treatment on the as sprayed coating was then studied by selecting two methods: in situ oxidation post treatment and classical thermal treatment. The two post treatments provided an increase of the main rutile phase and a decrease of both the size and the contents of porosity simultaneously.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Evaluation of the interaction between SiC, pre-oxidized FeCrAlMo with aluminized and pre-oxidized Fe-8Cr-2W in flowing PbLi

We report dissimilar materials interactions are a major concern when liquid metals are used as a working fluid. To simulate a dual-coolant PbLi blanket, chemical vapor deposited (CVD) SiC, pre-oxidized FeCrAlMo (APMT) and pre-oxidized aluminized coating on Fe-8Cr-2 W (F82H) specimens were exposed to flowing commercial Pb-17at.%Li with a peak temperature of 650 °C in a pre-oxidized APMT thermal convection loop (TCL) for 1000 h. Similar to prior results in static PbLi, the coated F82H showed small mass changes and limited degradation of room-temperature tensile properties. After exposure, the α-Al 2 O 3 on the surface coated F82H reacted with the PbLi to form LiAlO 2 . However, no significant Al coating loss or interdiffusion was observed. Mass transfer was observed between the APMT, TCL and the SiC specimens. Fe, Cr and Ni were dissolved into the molten flowing PbLi and transported through the TCL to react with the SiC specimens. Compared to a prior experiment with a majority of bare FeCrAl specimens that were exposed in a TCL with a peak temperature of 700 °C for 1000 h, the SiC reaction was reduced to only a few microns of carbides and silicides. Oxygen dissolved in the molten PbLi sustained the formation of an Al 2 O 3 scale on the surface of the coating and induced the formation of a thin surface SiO 2 layer on the surface of the SiC.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Substrate Effects When Using Photons to Make Perovskite Solar Cells

To shorten annealing time and minimize substrate heating, flash lamps that deliver short, intense light pulses, commonly called photonic curing, are used to replace thermal annealing using hot plates or ovens. This method is different from equilibrium heating in that the radiant energy is selectively absorbed by the film. The high-intensity light pulses produce a high peak temperature in the film. Because most processes follow Arrhenius behavior, reaching high temperatures allow chemical reactions/phase transformations to occur in a short time, significantly reducing the processing time. Often the results are non-intuitive. We will present fabricating flexible halide perovskite solar cells (PSCs) on indium tin oxide (ITO) coated Willow glass. The effect of ITO transmittance on the photonic curing of nickel nitrate sol-gel precursors into nickel oxide to fabricate hole transport layer and consequently the performance of PSCs. Unexpectedly, ITO samples processed by photonic curing show improved optical and electrical properties.

14 SOLAR ENERGY↗
DOE OSTI2020

Solar-thermal membrane for dewatering aqueous organic-acid solutions

A thermally conductive porous membrane has been developed to directly absorb solar energy and conduct heat that can effectively evaporate liquid water at the interface between the membrane and the bulk feed solution. Here, black, porous, thermally conductive graphite foam support is employed as an effective photothermal-energy absorber and heat conductor that heats up an aqueous feed solution to produce vapor. Graphite nanoparticle-slurry coating is applied onto the foam surface to reduce the pore size and generate a microporous membrane. Then, application of a dense graphene oxide membrane coating as an active separation layer on the microporous nanoparticle surface of internal foam channels allows vapor permeation of volatile molecules. Acetic acid/water solution was studied as a model feed system to experimentally demonstrate effective separation. This model vapor permeation system demonstrates excellent acetic acid separation, with a separation factor of 8.3, under simulated 0.7 sun irradiation. The membrane hydrophobicity and nanostructure, including pore size and surface chemistry, played a significant role in enabling high permselectivity of water vapor over acetic acid molecules, as well as liquid solution. Pore size reduction from open pores to a nonporous dense layer in the membrane enables effective separation of water vapor from the organic vapor, while it reduces the permeation flux. Also, the hydrophilicity of the membrane surface shows ~3 times higher permeation flux with higher permselectivity, compared with the hydrophobic membrane surface. This work introduces a process of directly using renewable energy instead of conventional heating to drive selective separation of water from organic acids.

14 SOLAR ENERGY↗
DOE OSTI2023

Stabilized lithium metal oxide electrode material and method of preparation

A stabilized lithium metal oxide cathode material comprises microparticles of lithium metal oxide in which individual particles thereof a core of lithium metal oxide and a coating of a different lithium metal oxide surrounding the core. There is an interface layer between the cores and the coatings in which there are gradients of metal ions in the direction of coating to core. The materials are made by a three stage process involving coprecipitating precursor metal hydroxide core particles at a controlled pH; coprecipitating a different metal hydroxide coating on the particles without controlling the pH; and then calcining the resulting coated precursor particles with lithium hydroxide to form the stabilized lithium metal oxide material.

Lipson, Albert L.↗
DOE OSTI2024

Stabilized lithium metal oxide electrode material and method of preparation

A stabilized lithium metal oxide cathode material comprises microparticles of lithium metal oxide in which individual particles thereof a core of lithium metal oxide and a coating of a different lithium metal oxide surrounding the core. There is an interface layer between the cores and the coatings in which there are gradients of metal ions in the direction of coating to core. The materials are made by a three stage process involving coprecipitating precursor metal hydroxide core particles at a controlled pH; coprecipitating a different metal hydroxide coating on the particles without controlling the pH; and then calcining the resulting coated precursor particles with lithium hydroxide to form the stabilized lithium metal oxide material.

Lipson, Albert L.↗
DOE OSTI2023

Computational fluid dynamics investigations of flow, heat transfer, and oxidation in heat recovery steam generator

Modern heat recovery steam generators (HRSGs) operate at elevated temperatures, leading to the formation of oxides inside the tubes of heat exchangers (HXs). This oxide growth reduces the heat recovery efficiency. Moreover, after reaching a certain critical thickness, some oxide scales detach from the tube surface (exfoliation), causing erosion damage to the components downstream. Predicting the metal temperature distribution and associated oxide thickness in the HXs of an HRSG can aid in mitigating these problems. Here, a computational fluid dynamics (CFD) model was developed within the commercial code STAR-CCM+ for the prediction of fluid flow, conjugate heat transfer, and associated oxidation in HRSGs. Moreover, a new Porous Media Model (PMM) method was developed to model the fin effect on the heat transfer in HX, which can substantially reduce the prohibitive computational costs of fin meshes. The developed CFD model was used to conduct a high-fidelity simulation of a real-scale HRSG to investigate flow, heat transfer, and oxide growth. The calculated oxide thickness on different tubes can be used to identify HX regions that require oxide-resistant coatings to prevent exfoliation and ensuing damages. Furthermore, this CFD framework can serve as a reference for future studies that intend to model and investigate high-temperature oxidation in HXs used for any applications.

42 ENGINEERING↗
DOE OSTI2022

Safeguards Considerations for Coated Particle Fuel Fabrication Facilities

This study aims to identify where existing fuel fabrication safeguards are limited in application to coated particle fuel fabrication facilities; perform a review of techniques that may be appropriate to address these limitations; and identify where further study is required. The purpose is to ensure the necessary technology and safeguards developments are established to facilitate safeguards-by-design for coated particle fuel fabrication facilities, analogous to the research and development (R&D) efforts in the advanced reactor space, including those requiring coated particle fuels and progress to higher technology readiness levels. Finally, this study will also help meet high priority objectives set forth by the IAEA in establishing safeguards R&D precedence and measurement/procedural standards at emerging fuel fabrication facilities. To achieve these objectives, the report is formatted to (1) distill relevant background information on fuel fabrication of oxide and coated particle fuels; (2) provide an overview of the fuel fabrication techniques for a reference oxide fuel fabrication facility and two selected TRISO fuel fabrication facilities; (3) develop facility models of safeguards approaches for the reference facility and the two TRISO facilities; and (4) identify any observed technology needs or gaps from this analysis.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

A round bobbin critical current measurement and thermal runaway simulation of REBCO coated conductors

A round bobbin test has been widely used to measure critical current Ic of practical superconductors including Nb–Ti, Nb3Sn, and Bi-2212 round strands at 4.2 K and in high magnetic fields but rarely used for rare earth-barium-copper-oxide (REBCO) coated conductor tapes. Here, we applies this method to REBCO tapes and test their Ic at 77 K, self-field, and 4.2 K with a magnetic field of 14 T applied parallel to the tape. The sample carries very high current densities; it is 1.3 m long and has a dense array of voltage taps that allows probing localized thermal runaways and correlation with Ic variations along the length. At 77 K, the Ic values of all sections were measured and found to be rather uniform. However, at 4.2 K, we found that a 3 cm section has 90% of the overall voltage drop and it went into thermal runaways upon further increasing current. Thus, at 4.2 K, we were prevented by localized thermal runaways and unable to determine Ic of most of the REBCO conductor sections; this behavior is different from Bi-2212 and Bi-2223 for which Ic of all turns of a round barrel sample can be determined. We simulate REBCO tapes during current ramping to a thermal runaway and analyze impacts of various factors including cooling, conductor n-values, and thickness of stabilizer on the thermal runaway current Iq. The combined experiments and simulations identify n-value as a crucial factor that leads to the observed differences between Bi-2212 and REBCO. Together with cooling and the standard deviation of Ic variations along the length, the n-value determines whether Iq is above or below the average Ic of a long piece of conductor and their ratio Iq/Ic,ave, greatly affecting quench detection and thermal runaway prevention strategies of Bi-2212 and REBCO magnets.

Mosat, Marek↗
DOE OSTI2020

Steam oxidation of ytterbium disilicate environmental barrier coatings with and without a silicon bond coat

The current generation of multilayer Si/Yb 2 Si 2 O 7 environmental barrier coatings (EBCs) are temperature limited by the melting point of Si, 1414°C. To investigate higher temperature EBCs, the cyclic steam oxidation of EBCs comprised of a single layer of ytterbium disilicate (YbDS) was compared to multilayered Si/YbDS EBCs, both deposited on SiC substrates using atmospheric plasma spray. In this work, after 500 1-h cycles at 1300°C in 90 vol%H2O-10 vol%air with a gas velocity of 1.5 cm/s, both multilayer Si/YbDS and single layer YbDS grew thinner silica scales than bare SiC, with the single layer YbDS forming the thinnest scale. Both coatings remained fully adherent and showed no signs of delamination. Silica scales formed on the single layer coating were significantly more homogeneous and possessed a markedly lower degree of cracking compared to the multilayered EBC. The single layer EBC also was exposed at 1425°C in steam with a gas velocity of 14 cm/s in an alumina reaction tube. The EBC reduced specimen mass loss compared to bare SiC but formed an extensive 2nd phase aluminosilicate reaction product. A similar reaction product was observed to form on some regions of the bare SiC specimen and appeared to partially inhibit silica volatilization. The 1425°C steam exposures were repeated with a SiC reaction tube and no 2nd phase reaction product was observed to form on the single layer EBC or bare SiC.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Multifunctional Films Deposited by Atomic Layer Deposition for Tailored Interfaces of Electrochemical Systems

A new strategy for electrochemical interfaces that utilizes multilayer films deposited by atomic layer deposition (ALD) is introduced. Manganese-rich and nickel-rich cathode oxides were coated with a novel bilayer film of metal fluorides. Subsequent exposure to prolonged, high-voltage electrochemical cycling vs graphite electrodes revealed that the bilayer film can greatly enhance the high-voltage stability of cathode oxides. In particular, in manganese-rich cells, capacity fade due to manganese dissolution was substantially reduced and impedance rise was virtually eliminated. Furthermore, in nickel-rich NMC-811 cells, impedance rise was reduced by ~80%, compared to the NMC-811 baseline, after ~300 h of high-voltage exposure during cycling. Here, the multilayer film strategy presents an exciting opportunity for tailoring designs and materials for electrochemical interfaces in advanced lithium-ion batteries and beyond.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

Photoelectron Spectroscopic Determination of the Interfacial Energetics of Metal Oxide Protection Layers on p-InP Photocathodes

The interfacial energetics between p-type InP and a series of metal oxides, including TiO 2 , Nb 2 O 5 , Ta 2 O 5 , and HfO 2 , were evaluated using X-ray photoelectron spectroscopy (XPS), ultraviolet photoelectron spectroscopy (UPS), and optical absorption spectroscopy. The energy of the conduction-band minimum ( E cb ) of TiO 2 and Nb 2 O 5 was more negative (i.e., further from the vacuum level) than the conduction-band minimum at the surface of InP ( E cb,s ), whereas E cb for Ta 2 O 5 and HfO 2 was more positive than E cb,s for InP. The data are consistent with the electrochemical behavior of p-InP coated with various metal oxide candidate protection layers, with TiO 2 and Nb 2 O 5 facilitating interfacial transfer of photogenerated minority-carrier electrons in p-InP photocathodes, and Ta 2 O 5 and HfO 2 blocking photogenerated electrons in p-InP from readily transferring across the oxide-coated photocathodes. The energy of the valence-band maximum ( E vb ) for all of the oxides was much more negative than E vb,s for InP, consistent with observations that these protection layers effectively block hole transport and consequently suppress oxidative degradation of the underlying p-InP photocathodes.

63 RADIATION, THERMAL, AND OTHER ENVIRON. POLLUTAN↗
DOE OSTI2020

Broadband, millimeter-wave antireflection coatings for large-format, cryogenic aluminum oxide optics

Here, we present two prescriptions for broadband (~77 -252 GHz), millimeter-wave antireflection coatings for cryogenic, sintered polycrystalline aluminum oxide optics: one for large-format (700 mm diameter) planar and plano–convex elements, the other for densely packed arrays of quasi-optical elements—in our case, 5 mm diameter half-spheres (called “lenslets”). The coatings comprise three layers of commercially available, polytetrafluoroethylene-based, dielectric sheet material. The lenslet coating is molded to fit the 150 mm diameter arrays directly, while the large-diameter lenses are coated using a tiled approach. We review the fabrication processes for both prescriptions, then discuss laboratory measurements of their transmittance and reflectance. In addition, we present the inferred refractive indices and loss tangents for the coating materials and the aluminum oxide substrate. We find that at 150 GHz and 300 K the large-format coating sample achieves (97±2)% transmittance, and the lenslet coating sample achieves (94±3)% transmittance.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Improved cycle stability and high-rate capability of LiNbO 3 -coated Li 3 VO 4 as anode material for lithium-ion battery

Lithium vanadate (Li 3 VO 4 ) has garnered considerable attention as an alternative negative electrode material for non-aqueous lithium-ion batteries due to its high capacity, energy efficiency, and stable discharge voltage. Nonetheless, the Li 3 VO 4 material displays a low rate capability, attributed mainly to its poor intrinsic electronic conductivity. Here, in this study, we report the synthesis of lithium niobate LiNbO 3 -coated Li 3 VO 4 (LVO@LNO) using a one-pot sol-gel method. The resulting LVO@LNO demonstrates a high reversible capacity of approximately 530 mAh/g, which is more than double that of free Li 3 VO 4 . To explore the effect of the LNO coating process on the morphological and structural properties, Raman, XRD, operando XRD, XPS, SEM and HTEM analyses were conducted. To explain the enhancement of electronic conductivity in our modified material after a LiNbO 3 coating, we conducted an Ex-Situ electrochemical impedance (EIS) and Density Functional Theory (DFT) computational study. Additionally, we designed a full cell utilizing a 1 wt% LNO-coated LVO anode and NMC-811 cathode. The cell yielded an output voltage of approximately 2.8 V with a high initial specific capacity of 350 mAh/g versus to the anode, at 1C with a capacity retention of 85 % after 100 cycles.

25 ENERGY STORAGE↗
DOE OSTI2025

Investigation of High-Temperature Compatibility of Select Oxides with Yttrium Hydride for Micro and Space Reactor Applications

Yttrium hydride is a promising material for a high-temperature neutron moderator in advanced micro and space reactors due to its high hydrogen density and relative thermal stability compared to other metal hydrides. However, yttrium hydride desorbs hydrogen rapidly at temperatures above 800°C, which is below the operational temperature range of some reactor designs. A hydrogen barrier coating of oxide on the hydride surface may inhibit hydrogen loss at 800°C and beyond, but the high-temperature compatibility between yttrium hydride and many oxides is currently unknown. The high-temperature compatibility of Al 2 O 3 , MgO, and Y 2 O 3 with YH 1.92 was examined by subjecting mixed oxide–hydride pellets to a 1200°C heat treatment then using a combination of diffractometry, microscopy, and spectroscopy to determine changes in the pellet composition as a result. Yttrium scavenged oxygen from both Al 2 O 3 and MgO to form Y 2 O 3 , resulting in significant loss of YH 1.92 . Yttrium reacted with reduced aluminum to form YAl 2 and several other compounds. Reduced magnesium volatilized above 1091°C and vacated the pellet. Only Y 2 O 3 did not appreciably react with YH 1.92 . Of the three oxides tested, only Y 2 O 3 was compatible with YH 1.92 at 1200°C based on the experimental criteria.

compatibility↗
DOE OSTI2021

High-temperature oxidation and quenching of chromium-coated zirconium alloy ATF cladding tubes with and w/o pre-damage

Chromium-coated zirconium alloys are one of the promising candidates for accident-tolerant fuel cladding (ATF) tubes for light water reactors (LWRs). In this study, the high temperature oxidation and degradation of two types of Cr coatings (cold spray and physical vapor deposition) with and without pre-damage by scratches were investigated on prototype rod segment samples filled with ZrO 2 pellets and tightly sealed with welded end caps. Isothermal tests at 1100 and 1200 °C were terminated by quenching with water; transient tests were performed up to 1500–1600 °C until complete coating failure. The positive effect of both types of Cr coatings was observed in all tests. Pre-damaged specimens showed only locally increased oxidation of the scratched zone, but no negative effects on the adjacent Cr coating. Finally, the behavior of the two types of coatings is compared and the degradation mechanisms are discussed based on hydrogen release data, extensive metallographic post-test examinations, and the current state of global research.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Realizing efficient operations of Ni-cermet-based fuel cells on hydrocarbons via an in situ self-assembled metal/oxide nano-heterostructured catalyst

Operating Ni-cermet-based fuel cells on hydrocarbons is charming by largely hindered by poor coking tolerance and severe deterioration. Here, in this study, we report an effective metal/oxide nano-heterostructured catalyst with a nominal composition of Pr 0.95 Ru 0.05 O 2-δ (PRO), which is in situ self-assembled to a Pr 0.95 Ru 0.05-x O 2-δ oxide frame coated with Ru metallic nanoparticles (denoted as Ru/PRO) under the operation condition. When applied to the Ni-cermet (Ni-YSZ) anodes, the cells achieve decent peak power densities of 1.784 and 1.870 W cm -2 on CH 4 and C 3 H 8 with only 3% H 2 O at 750 °C, respectively. Moreover, the cells with Ru/PRO-coated anode demonstrate excellent durability when operated on CH 4 for ~ 220 h and C 3 H 8 for ~115 h. It is demonstrated that the Ru/PRO generates hydroxyl species that react with carbon species, followed by the formation of COH intermediates on Ni anode surfaces for removing the coking, as confirmed by experiments and computations.

30 DIRECT ENERGY CONVERSION↗