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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 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
NASA NTRS2007

Balloon for Long-Duration, High-Altitude Flight at Venus

A document describes a 5.5-m-diameter, helium-filled balloon designed for carrying a scientific payload having a mass of 44 kg for at least six days at an altitude of about 55 km in the atmosphere of Venus. The requirement for floating at nearly constant altitude dictates the choice of a mass-efficient spherical super-pressure balloon that tracks a constant atmospheric density. Therefore, the balloon is of a conventional spherical super-pressure type, except that it is made of materials chosen to minimize solar radiant heating and withstand the corrosive sulfuric acid aerosol of the Venusian atmosphere. The shell consists of 16 gores of a multilayer composite material. The outer layer, made of polytetrafluoroethylene, protects against sulfuric acid aerosol. Next is an aluminum layer that reflects sunlight to minimize heating, followed by an aluminized polyethylene terephthalate layer that resists permeation by helium, followed by an aromatic polyester fabric that imparts strength to withstand deployment forces and steady super-pressure. A polyurethane coat on the inner surface of the fabric facilitates sealing at gore-to-gore seams. End fittings and seals, and a tether connecting the end fittings to a gondola, are all made of sulfuric-acid-resistant materials.

Hall, Jeffrey↗
NASA NTRS2009

Citric Acid Passivation of Stainless Steel

Passivation is a process for cleaning and providing corrosion protection for stainless steel. Currently, on Kennedy Space Center (KSC), only parts passivated with nitric acid are acceptable for use. KSC disposes of approximately 125gal of concentrated nitric acid per year, and receives many parts from vendors who must also dispose of used nitric acid. Unfortunately, nitric acid presents health and environmental hazards. As a result, several recent industry studies have examined citric acid as an alternative. Implementing a citric acid-based passivation procedure would improve the health and environmental safety aspects of passivation process. However although there is a lack of published studies that conclusively prove citric acid is a technically sound passivation agent. In 2007, NASA's KSC Materials Advisory Working Group requested the evaluation of citric acid in place of nitric acid for passivation of parts at KSC. United Space Alliance Materials & Processes engineers have developed a three-phase test plan to evaluate citric acid as an alternative to nitric acid on three stainless steels commonly used at KSC: UNS S30400, S41000, and S17400. Phases 1 and 2 will produce an optimized citric acid treatment based on results from atmospheric exposure at NASA's Beach Corrosion Facility. Phase 3 will compare the optimized solution(s) with nitric acid treatments. If the results indicate that citric acid passivates as well or better than nitric acid, NASA intends to approve this method for parts used at the Kennedy Space Center.

Yasensky, David↗
DOE OSTI2022

Comprehensive insights into competitive oxidation/sulfidation reactions on binary ferritic alloys at high temperatures

Interpreting high-temperature corrosion induced by mixed-gas atmospheres is challenging due to the different contributions of oxidizing gases. In this work, a comprehensive study on the combined oxidation/sulfidation using label molecules is presented. Fe-Cr model alloys with 2 wt% and 9 wt% Cr were isothermally exposed using a volumetric mixture of 0.5%S 16 O 2 /27%H 2 18 O and 0.5%S 16 O 2 /7%H 2 18 O at 650 °C for 5 h and then characterized by secondary ion mass spectroscopy (SIMS). Additionally, the reactions were followed in-situ utilizing energy dispersive X-ray diffraction. The study showed that both S 16 O 2 and H 2 18 O contribute to the oxidation of the alloys but to different extents depending on the Cr-content.

36 MATERIALS SCIENCE↗
NASA NTRS1929

Corrosion Embrittlement of Duralumin V : Results of Weather-Exposure Tests

In a series of weather exposure tests of sheet duralumin, upon which accelerated corrosion tests in the laboratory by the wet-and-dry corrosion method in a sodium chloride solution has already been carried out, a close parallelism between the results of the two kinds of tests was found to exist. The exposure tests showed that the lack of permanence of sheet duralumin is largely, if not entirely, due to corrosion. A corrosion attack of an intercrystalline nature is very largely responsible for the degree of embrittlement produced. The rate of embrittlement was greatly accelerated by a marine atmosphere and by the tropical climate. Variations in corrosion and embrittlement are noted in relation to heat treatment, cold working, and types of protective coatings.

Rawdon, Henry S↗
NASA NTRS1977

The stress corrosion resistance and the cryogenic temperature mechanical properties of hot rolled Nitronic 32 bar material

The ambient and cryogenic temperature mechanical properties and the ambient temperature stress corrosion properties of hot rolled and centerless ground Nitronic 32 stainless steel bar material are presented. The mechanical properties of longitudinal specimens were evaluated at test temperatures from ambient to liquid hydrogen. The tensile test data indicated increasing smooth tensile strength with decreasing temperature to liquid hydrogen temperature. However, below -200 F (-129.0 C) the notched tensile strength decreased slightly and below -320 F (-196.0 C) the decrease was significant. The elongation and reduction of area decreased drastically at temperatures below -200 F (-129.0 C). The Charpy V-notched impact energy decreased steadily with decreasing test temperature. Stress corrosion tests were performed on longitudinal tensile specimens stressed to 0, 75, and 90 percent of the 0.2 percent yield strength and on transverse 'C'-ring specimens stressed to 75 and 90 percent of the yield strength and exposed to: alternate immersion in a 3.5 percent NaCl bath, humidity cabinet environment, and a 5 percent salt spray atmosphere. The longitudinal tensile specimens experienced no corrosive attack; however, the 'C'-rings exposed to the alternate immersion and to the salt spray experienced some shallow etching and pitting, respectively. Small cracks appeared in two of the 'C'-rings after one month exposure to the salt spray.

Montano, J. W. L.↗
DOE OSTI2022

FY2022 Status Report: Cold Spray for Canister SCC Mitigation and Repair

This progress report describes work performed during FY22 at Sandia National Laboratories (SNL) to assess the corrosion performance of cold spray coatings to enable optimization of cold spray for the purposes of mitigation and/or repair of potentially susceptible regions, corrosion, or stress corrosion cracking (SCC) in austenitic stainless steel for spent nuclear fuel (SNF) storage. Of particular concern is SCC, by which a through-wall crack could potentially form in a canister outer wall over time intervals that may be shorter than possible dry storage times. In FY21, initial corrosion explorations of cold spray coating were evaluated and in FY22, an expanded set of cold spray coatings with in-depth analysis of post-exposure accelerated testing was explored. Additionally, relevant atmospheric exposure testing was carried out and initial results are presented herein. The corrosion attack from the accelerated testing and more realistic atmospheric exposures environments were compared to identify potentially deleterious factors for corrosion as well as help to understand the applicability of accelerated testing for cold spray optimization. This initial analysis will help to enable optimization of the corrosion resistance cold spray, one of the more promising coating and repair techniques, for potential application in an SNF environment. Learnings from both are summarized, and implications and future work are presented in this report.

36 MATERIALS SCIENCE↗
DOE OSTI2020

The Long-term Storage of ILW: Building Stores with the Appropriate Environmental Controls - 20294

In the UK, containers for the storage and disposal of intermediate level radioactive waste (ILW) typically use stainless steel due to its excellent mechanical properties and corrosion resistance. The period of interim storage before a disposal facility is available, however, is longer than available engineering experience with stainless steels in relevant environmental conditions. Additionally, after disposal the ability of ILW containers to withstand further periods of exposure to the environment is expected to provide substantial benefits to the operation of a disposal facility and the safety case underpinning its closure. For these reasons, although there have been no instances of failure of stainless steels in indoor storage conditions, a focused R and D programme has been carried out to identify the environmental envelope over which the material does not significantly degrade. In this study we summarise experimental and modelling studies carried out over the last decade to build a solid mechanistic understanding of the corrosion behaviour of stainless steels in indoor atmospheric conditions. We then identify suitable environmental regimes to minimise the risk of degradation processes and explore approaches to monitoring the storage conditions to gain confidence in the long-term performance of the system. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS1959

Halogen-Containing Gases as Boundary Lubricants for Corrosion-Resistant Alloys at 1200 F

The extreme temperatures anticipated for lubricated parts in advanced flight powerplants dictate the consideration of unconventional methods of lubrication such as solid lubricants and the reactive gases described in the present research. These halogen-containing "reactive" gases such as dichlorodifluoromethane, CF2Cl2, are among the most stable of organic molecules. The high "flash" temperatures generated at the contacting asperities as a result of frictional heat are sufficient to cause local decomposition of the halogen-containing gases. The active atoms thus released (e.g., chlorine) then react with the metal to be lubricated to form halides capable of effective lubrication. The presence of small amounts of a sulfur-containing gas (e.g., 1 percent sulfur hexafluoride, SF6) was found to catalyze the formation of metal halides. Friction and wear studies were made with a hemisphere (3/16-in. rad.) rider sliding in a circumferential path on the flat surface of a rotating disk (2 1/2-in. diam.). The specimens of corrosion-resistant 2 alloys were run in an atmosphere of the various gases with a load of 1200 grams, a sliding velocity of 120 feet per minute, and temperature from 75 to 1200 F. An effective lubricant for ferritic materials (M-1 tool steel) was CF2Cl2, but significant corrosion occurred above 600 F. Corrosion evaluation in CF2Cl2 suggested a number of nickel- and cobalt-base alloys for additional lubrication study. Several combinations of gases and these metals were found to lubricate to 1200 F without excessive corrosion. The gases were CF2Cl2 Plus 1 percent SF6, monobromotrifluoromethane CF3Br plus 1 percent SF6, dibromodifluoromethane CF2Br2, iodotrifluoromethane, CF3I, and I2. Careful selection of metals and gas are necessary for successful lubrication over specific temperature ranges. Optimum combinations give friction coefficients as low as 0.05 without

Buckley, Donald H.↗
NASA NTRS2011

Corrosion Protection of Launch Infrastructure and Hardware Through the Space Shuttle Program

Corrosion, the environmentally induced degradation of materials, has been a challenging and costly problem that has affected NASA's launch operations since the inception of the Space Program. Corrosion studies began at NASA's Kennedy Space Center (KSC) in 1966 during the Gemini/Apollo Programs with the evaluation of long-term protective coatings for the atmospheric protection of carbon steel. NASA's KSC Beachside Corrosion Test Site, which has been documented by the American Society of Materials (ASM) as one of the most corrosive, naturally occurring environments in the world, was established at that time. With the introduction of the Space Shuttle in 1981, the already highly corrosive natural conditions at the launch pad were rendered even more severe by the acidic exhaust from the solid rocket boosters. In the years that followed, numerous efforts at KSC identified materials, coatings, and maintenance procedures for launch hardware and equipment exposed to the highly corrosiye environment at the launch pads. Knowledge on materials degradation, obtained by facing the highly corrosive conditions of the Space Shuttle launch environment, as well as limitations imposed by the environmental impact of corrosion control, have led researchers at NASA's Corrosion Technology Laboratory to establish a new technology development capability in the area of corrosion prevention, detection, and mitigation at KSC that is included as one of the "highest priority" technologies identified by NASA's integrated technology roadmap. A historical perspective highlighting the challenges encountered in protecting launch infrastructure and hardware from corrosion during the life of the Space Shuttle program and the new technological advances that have resulted from facing the unique and highly corrosive conditions of the Space Shuttle launch environment will be presented.

Calle, L. M.↗
NASA NTRS1982

Bearing fatigue investigation 3

The operating characteristics of large diameter rolling-element bearings in the ultra high speed regimes expected in advanced turbine engines for high performance aircraft were investigated. A high temperature lubricant, DuPont Krytox 143 AC, was evaluated at bearing speeds to 3 million DN. Compared to the results of earlier, similar tests using a MIL-L-23699 (Type II) lubricant, bearings lubricated with the high density Krytox fluid showed significantly higher power requirements. Additionally, short bearing lives were observed when this fluid was used with AISI M50 bearings in an air atmosphere. The primary mode of failure was corrosion initiated surface distress (fatigue) on the raceways. The potential of a case-carburized bearing to sustain a combination of high-tangential and hertzian stresses without experiencing race fracture was also investigated. Limited full scale bearing tests of a 120 mm bore ball bearing at a speed of 25,000 rpm (3 million DN) indicated that a carburized material could sustain spalling fatigue without subsequent propagation to fracture. Planned life tests of the carburized material had to be aborted, however, because of apparent processing-induced material defects.

Nahm, A. H.↗
NASA NTRS2015

NASA's Corrosion Technology Laboratory at the Kennedy Space Center: Anticipating, Managing, and Preventing Corrosion

The marine environment at NASAs Kennedy Space Center (KSC) has been documented by ASM International (formerly American Society for Metals) as the most corrosive in North America. With the introduction of the Space Shuttle in 1981, the already highly corrosive conditions at the launch pads were rendered even more severe by the highly corrosive hydrochloric acid (HCl) generated by the solid rocket boosters (SRBs). Numerous failures at the launch pads are caused by corrosion. The structural integrity of ground infrastructure and flight hardware is critical to the success, safety, cost, and sustainability of space missions. NASA has over fifty years of experience dealing with unexpected failures caused by corrosion and has developed expertise in corrosion control in the launch and other environments. The Corrosion Technology Laboratory at KSC evolved, from what started as an atmospheric exposure test site near NASAs launch pads, into a capability that provides technical innovations and engineering services in all areas of corrosion for NASA, external partners, and customers.This paper provides a chronological overview of NASAs role in anticipating, managing, and preventing corrosion in highly corrosive environments. One important challenge in managing and preventing corrosion involves the detrimental impact on humans and the environment of what have been very effective corrosion control strategies. This challenge has motivated the development of new corrosion control technologies that are more effective and environmentally friendly. Strategies for improved corrosion protection and durability can have a huge impact on the economic sustainability of human spaceflight operations.

Corrosion Control↗
NASA NTRS2008

Extreme Environment Technologies for Space and Terrestrial Applications

Over the next decades, NASA's planned solar system exploration missions are targeting planets, moons and small bodies, where spacecraft would be expected to encounter diverse extreme environmental (EE) conditions throughout their mission phases. These EE conditions are often coupled. For instance, near the surface of Venus and in the deep atmospheres of giant planets, probes would experience high temperatures and pressures. In the Jovian system low temperatures are coupled with high radiation. Other environments include thermal cycling, and corrosion. Mission operations could also introduce extreme conditions, due to atmospheric entry heat flux and deceleration. Some of these EE conditions are not unique to space missions; they can be encountered by terrestrial assets from the fields of defense,oil and gas, aerospace, and automotive industries. In this paper we outline the findings of NASA's Extreme Environments Study Team, including discussions on state of the art and emerging capabilities related to environmental protection, tolerance and operations in EEs. We will also highlight cross cutting EE mitigation technologies, for example, between high g-load tolerant impactors for Europa and instrumented projectiles on Earth; high temperature electronics sensors on Jupiter deep probes and sensors inside jet engines; and pressure vessel technologies for Venus probes and sea bottom monitors. We will argue that synergistic development programs between these fields could be highly beneficial and cost effective for the various agencies and industries. Some of these environments, however, are specific to space and thus the related technology developments should be spear headed by NASA with collaboration from industry and academia.

extreme environments↗
NASA NTRS1986

Corrosion of metals and alloys in sulfate melts at 750 C

The corrosion of Ni, Co, Ni-10Cr, Co-21Cr, and IN738 was studied at 750 C in the presence of molten sulfate mixtures (Na2SO4-Li2SO4 and Na2SO4-CoSO4) and in an atmosphere consisting of O2 + 0.12 percent SO2-SO3. The corrosion was observed to be similar for both Na2SO4-Li2SO4 and Na2SO4-CoSO4 melts. The corrosion of Ni and Co took place by the formation of a mixed oxide plus sulfide scale, very similar to the corrosion in SO2 or SO3 alone. The initial stage for the corrosion of Ni-10Cr involved the formation of a thick NiO + Ni3S2 duplex scale, and Cr sulfide was formed during the later stages. A pitting type of morphology was observed for both Co-21Cr and IN738. The pit was Cr sulfide at the beginning, and subsequently the sulfides oxidized to Cr2O3. A base-metal oxide layer was present above the pit, and this was observed to be formed very early in the corrosion process. A mechanism is proposed to explain this. In general, the formation of sulfides appears to be the primary mode of degradation in mixed sulfide melts.

Misra, A. K.↗
DOE OSTI2022

Mitigation of Molten Salt Corrosion

The desire to increase the peak operational temperature of Concentrated Solar Power (CSP) plants to lower the levelized cost of CSP-derived electricity, has led to consideration of an earth-abundant, low-cost, thermally-stable, molten MgCl 2 -KCl-NaCl (40-40-20 mole%) salt for high-temperature thermal energy storage and heat transfer. The reliable, long-term containment of such a molten salt is challenging, however, due to the corrosion of cost-effective, high-temperature structural metal alloys in this salt (particularly if this salt is contaminated with oxygen-bearing species). This project has been focused on: i) development of equipment for evaluating corrosion kinetics in molten chlorides under well-controlled thermal, fluid dynamic, and atmospheric conditions at CSP-relevant temperatures, ii) use of such equipment to evaluate the influence of forced convection on corrosion kinetics (to determine the role of liquid phase diffusion on such corrosion), and iii) identifying a corrosion-mitigation strategy that can be industrially applied to achieve a projected annual corrosion ≤30 μm at CSP-relevant temperatures. The overall goals of this project have been: i) to understand the rate-limiting step(s) and associated kinetic laws governing corrosion in molten chlorides at 750°C, ii) to determine key operational parameters affecting the corrosion kinetics in molten salts, and iii) to demonstrate the tailoring of such parameters to appreciably reduce such corrosion.

14 SOLAR ENERGY↗
NASA NTRS1981

Seacoast stress corrosion cracking of aluminum alloys

The stress corrosion cracking resistance of high strength, wrought aluminum alloys in a seacoast atmosphere was investigated and the results were compared with those obtained in laboratory tests. Round tensile specimens taken from the short transverse grain direction of aluminum plate and stressed up to 100 percent of their yield strengths were exposed to the seacoast and to alternate immersion in salt water and synthetic seawater. Maximum exposure periods of one year at the seacoast, 0.3 or 0.7 of a month for alternate immersion in salt water, and three months for synthetic seawater were indicated for aluminum alloys to avoid false indications of stress corrosion cracking failure resulting from pitting. Correlation of the results was very good among the three test media using the selected exposure periods. It is concluded that either of the laboratory test media is suitable for evaluating the stress corrosion cracking performance of aluminum alloys in seacoast atmosphere.

Humphries, T. S.↗
NASA NTRS1991

Oxidation-chlorination of binary Ni-Cr alloys in flowing Ar-O2-Cl2 gas mixtures at 1200 K

Nickel-chromium alloys are resistant to oxidation because of the selective oxidation of chromium to form a protective Cr2O3 scale. In chlorine-containing environments, volatile corrosion products can also be formed. The mixed oxidation-chlorination of Ni-4.5Cr, Ni-13.8Cr, and Ni-26.5Cr (by weight) alloys in Ar-O2-Cl2 gas mixtures is investigated using thermogravimetric analysis and atmospheric-pressure-sampling mass spectrometry, followed by examination of the corrosion products using scanning electron microscopy and X-ray diffraction analysis. The overall kinetics of the corrosion are affected by the relative amounts of oxides and chlorides formed and the composition of the oxide corrosion products.

Mcnallan, M. J.↗
DOE OSTI2022

An Innovative Zero-Liquid Discharge Intermediate-Cold-Liquid Eutectic-Freeze Desalination System

A novel freeze desalination technology is presented for purification of water produced from various industrial processes, including oil and gas extraction. The main innovative idea is introducing a water-immiscible intermediate-cold-liquid (ICL) medium which absorbs the cold from a refrigeration cycle and transfers it to a freezing chamber where it is mixed with brine. The cold ICL enters the freezing chamber at temperatures between -10°C to -30°C. Precooled brine in injected into the freezing chamber and pure water freezes out of the brine upon mixing with the ICL. The rate of freezing inside the chamber is controlled by adjusting the flow rate of the cold ICL relative to the inlet brine. Both eutectic freeze and non-eutectic freezing are possible by controlling the temperature of the freezing chamber. The solid-liquid slurry created in the freezing chamber flows to a filter separation unit after passing through a separation column. The ice crystals are separated from the liquid by a rotary filter device. The collected ice is rinsed by a centrifugal unit. The rinsed ice is melted to produce fresh water. The developed technology resolves the issues common to current freeze-desalination systems while offering superior heat transfer performance ascribed to direct-contact between the cooling medium and the brine in addition to producing solid salt and pure water. The system operates under atmospheric pressure. The low operation temperature minimizes the corrosion issues common in systems exposed to brine. Also, due to the low operating temperature, there are no concerns about evaporation of volatile organics from the produced water during the treatment. The developed technology effectively eliminates the use of chemicals for pretreatment of brine. The system can be constructed from commercially available components. Extensive testing using a lab-scale prototype by using synthetic brine and actual produced water with TDS values from 50,000 ppm to 300,000 ppm showed that freshwater could be achieved with relatively small dependency on the quality of the input brine. The quality of the treated water was found to be mainly a function of the duration of the centrifugal process. Treated water with TDS as low as 200 ppm could be achieved in the tests. Thermo-economic modeling coupled with system level thermochemical process model were developed for prediction of the LCOW. The LCOW was predicted to be $\$$0.50 to $\$$0.90 per barrel of produced water. The potential markets for deployment of the technology are the oil and gas, in-land thermoelectric powerplants, RO desalination plants, and mining industry.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗