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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Development of an immersion fiber optic Raman probe for real-time analysis of molten materials

This study presents an advancement in high-temperature Raman spectroscopy, specifically for analyzing molten materials. It introduces an approach by integrating a fiber-optic Raman probe with a copper block protection system designed to endure extreme thermal conditions. The copper block features an open port designed to accommodate an external telescope with a 3 cm focal length, enabling Raman spectra collection in challenging high-temperature environments. A built-in gas channel ensures a continuous flow of argon gas to prevent flux intrusion. The robust copper block acts as a reliable shield, safeguarding the fiber-optic Raman probe within molten materials. This enhancement maintains the probe's integrity and significantly improves its resilience, making it ideal for rigorous investigations of molten substances. This advancement is particularly relevant in metallurgy, where flux materials impact production quality and efficiency. The ability to acquire Raman signals under elevated thermal conditions offers opportunities for studying molecular dynamics, compositional changes, and chemical interactions within molten substances. This introduced direct immersion probing technique has implications, benefiting both scientific and industrial fields. It holds promise for advancing research and exploration in various contexts, from fundamental scientific inquiries to practical applications in metallurgical processes, where flux materials are critical for optimizing production quality and efficiency. Furthermore, this approach enhances the capabilities of high-temperature Raman spectroscopy, making it a valuable tool for investigating molten materials and their properties in diverse settings.

Argon↗
DOE OSTI2023

Structural analysis of molten materials by a remote fiber optic Raman sensor

This study presents a novel in situ high-temperature fiber optic Raman probe that enables the study of the physical properties and structure of molten samples at temperatures up to 1400 °C. To demonstrate the functionality of the high-temperature fiber optic Raman probe, different composition mold fluxes were evaluated in this report. The Raman spectra at flux molten temperature were successfully collected and analyzed. A deconvolution algorithm was employed to identify peaks in the spectra associated with the molecular structure of the components in each sample. Here, the experimental results demonstrate that the composition-dependent Raman signal shift can be detected at high temperatures, indicating that molten materials analysis using a high-temperature Raman system shows significant promise. This flexible and reliable high-temperature Raman measurement method has great potential for various applications, such as materials development, composition and structure monitoring during high-temperature processing, chemical identification, and process monitoring in industrial production.

47 OTHER INSTRUMENTATION↗
DOE OSTI2021

A Facile, One-Step Synthesis for Core–Shell Perovskite Materials via Molten Salt

Core–shell La 0.6 Sr 0.4 Co 0.2 Fe 0.8 O 3 (LSCF)–La 0.8 Sr 0.2 MnO 3 (LSM) heterostructure crystalline materials have been synthesized in a simple, one-step feeding method via a KNO 3 molten salt solvent. Two-phase perovskite composites can be synthesized in times as short as 10 minutes and is demonstrated for the first time in a molten salt. Further, a combination of X-ray diffraction and S/TEM energy dispersive X-ray spectroscopy has been utilized to confirm the formation of an LSM shell on LSCF cores in all samples when adjusting dwell time, core size, weight ratio between core and shell precursors, and weight ratio of powder to salt. Specifically, decreasing the LSCF core size increases core–shell yield. Smaller cores introduce a greater density of facets on the crystal surface and provide more favorable sites for LSM heterogeneous nucleation.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Effect of oxide impurities on the corrosion behavior of structural materials in molten LiF-NaF-KF

The corrosion of materials in molten fluoride salts is largely influenced by the presence of impurities in the salt. Very few studies have been done on the effect of oxide impurities on the corrosion of structural alloys in molten fluoride salts. In this study, corrosion behavior of selected alloys was studied in molten FLiNaK with the addition of different oxides such as Li 2 O, NiO, and Cr 2 O 3 . The results show that addition of oxides can lead to significant effects on this corrosion, depending on the type and amount of oxide added and the alloy being used.

14 SOLAR ENERGY↗
DOE OSTI2023

Effect of metal fluorides on the corrosion of structural materials in molten LiF-NaF-KF

The corrosion of structural materials in molten fluoride salts is predominantly caused by the presence of impurities in the salt. Here, this study focuses on understanding the corrosion behavior of selected alloys in molten FLiNaK salt with addition of similar quantities of metal fluoride impurities such as CrF 2 , CrF 3 , FeF 2 , FeF 3 , and NiF 2 . The results show that the presence of selected metal fluoride impurities increases the extent of corrosion of the selected alloys in molten FLiNaK salt, with the exact effect depending on the thermodynamic stability of the fluoride impurity added as well as the composition of the structural alloy studied.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Establishing a Design Strategy for Corrosion Resistant Structural Materials in Molten Salt Technologies

To address the gap in material design strategies for structural components in molten salt-powered technologies, the current work aimed to identify key parameters governing corrosion induced degradation of materials during exposures in molten halide salts. The applicability of the data on dissolution rates of pure metals (e.g., Cr) in a given molten salt to enable predictions of corrosion behavior of multicomponent binary and ternary Fe-based model and Ni-based commercial alloys isothermally exposed in the purified KCl-MgCl 2 in quartz capsules at 700 and 800°C was evaluated. The influence of alloy chemistry on initial dissolution rates and the consequent impact on the time-dependent corrosion induced microstructural evolution in the alloy subsurface was predicted with a coupled thermodynamic-kinetic model. Finally, the model was well able to predict the Cr depletion in all investigated alloys demonstrating the ability of the proposed approach to enable a unique design strategy for structural materials in molten salts.

36 MATERIALS SCIENCE↗
DOE OSTI2021

First steps toward predicting corrosion behavior of structural materials in molten salts

To address the need for physics-based models to predict corrosion behavior of materials in molten salts, here we propose potential methods to aid in selection of optimum materials for structural components in molten salt powered technologies. In the present work, the role of alloy thermodynamics and kinetics on governing corrosion rates of Ni-based alloys will be discussed combining experimental and computational methods. A few strategies are presented to quantify corrosion rates of Ni-based materials isothermally exposed in purified KCl-MgCl 2 salts at 600° C-800° C. The influence of capsule material, potential corrosion products and role of alloy composition on the observed corrosion rates was discussed with coupled thermodynamic-kinetic models. Larger depths of corrosion attack were observed in alloy 230 specimens compared to other alloys under similar conditions was attributed to the much higher chemical activity of Cr in the alloy that results in a larger Cr chemical potential gradient.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Stability of ceramic matrix materials in molten hydroxide under oxidizing and reducing conditions

The degradation mechanism of ceramic matrix materials used as molten hydroxide electrolyte support for steam electrolysis cells, is not well documented. In this study, we have investigated the structural and chemical stability of non-oxide and oxide ceramics (SiC, YSZ, Li 2 ZrO 3, LiAlO 2 , and SrZrO 3 ) in the presence of molten hydroxide under oxidizing and reducing conditions with humidity levels of 3 and 85% at 550 °C. SiC, YSZ, Li 2 ZrO 3 and LiAlO 2 showed structural and chemical changes due to dissolution of the ceramic particles in the hydroxide melt followed by precipitation. The SrZrO 3 powder, on the other hand, remained both chemically and structurally stable during 500 h test under both oxidizing and reducing atmospheres. The findings of a stable ceramic matrix in molten hydroxide contribute to the enhancement of the durability and performance of intermediate temperature water electrolysis system.

08 HYDROGEN↗
DOE OSTI2025

Single Crystalline Na 0.67 Ni 0.33 Mn 0.67 O 2 Positive Electrode Material via Molten Salt Synthesis for Sodium Ion Batteries

P2-layered Na 0.67 Ni 0.33 Mn 0.67 O 2 (NNMO) has emerged as a promising positive electrode material for sodium ion batteries due to its appealing electrochemical properties. Synthesis of polycrystalline NNMO (PC-NNMO) materials through conventional calcination of solid precursors remains the prevailing method, where heating occurs in a dry environment with air or O 2 . On the other hand, the molten salt method, where precursors are submerged in molten salt medium during calcination, emerged in recent years to be a scalable technique for more controlled crystal growth and uniform morphology in a variety of materials. Here, we utilize the molten salt method to synthesize single crystalline NNMO (SC-NNMO) materials with enhanced electrochemical properties. The SC-NNMO material exhibits an initial specific discharge capacity of 95 mAh g –1 at a 0.1C rate, retaining approximately 88.5% of its capacity after 100 cycles over a wide voltage range of 2.0–4.2 V. Furthermore, SC-NNMO maintains a capacity retention of 83.9% after 300 cycles at a 1C rate compared to 66.6% for PC-NNMO, indicating excellent long-term cycling stability. This stability is further confirmed by the performance of an SC-NNMO//hard carbon full cell, which retains 90.3% of its capacity after 200 cycles at 1C within a voltage window of 1.9–4.1 V. The enhancement in stability of the SC-NNMO sample is attributed to the single crystalline structure suppressing the undesired P2–O2 phase transition at high voltage. This study also presents an easy, efficient, and straightforward molten salt process for SC-NNMO material synthesis, offering valuable insights into the potential application of such methodology for the large-scale, cost-effective production of various sodium-layered transition metal oxide positive electrode materials for SIBs.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2023

Laser drilling and machining enhancement using gated CW and short pulsed lasers

The present disclosure relates to a laser system for processing a material. The system may make use of a laser configured to intermittently generate a first laser pulse of a first duration and a first average power, at a spot on a surface of the material being processed, and a second laser pulse having a second duration and a second peak power. The second duration may be shorter than the first duration by a factor of at least 100, and directed at the spot. The second laser pulse is generated after the first laser pulse is generated. The first laser pulse is used to heat the spot on the surface of the material, while the second laser pulse induces a melt motion and material ejection of molten material from the melt pool.

Ly, Sonny S.↗
DOE OSTI2023

Smart Refractory Sensors Development for Corrosion and Erosion Monitoring in High Temperature Systems

To optimize the operation and functioning of high temperature systems such as slagging gasifiers, coal boilers and glass/steel melters, it is important to monitor corrosion and erosion of refractory used in such systems. Corrosion test strategies are generally based on continuous gravimetric and chemical reactivity monitoring at operational temperatures (750°-1500°C). Both thermocouples and failure sensors and arrays would be useful to monitor the health of any refractory or coatings in these systems. Many of such type of sensors are installed into the systems through open access ports within the refractory; however, there are some disadvantages of this approach where corrosive/erosive gas and molten materials can penetrate and compromise the system. The current work presents the development and performance demonstration of smart refractory with embedded high temperature sensors such as thermocouples, thermistors, and various spallation/crack monitoring sensors, which may be used within a variety of refractory brick in different high temperature processes and applications. The main feature of this technology is that electroceramic based sensors are embedded into smart refractory without significantly impact to the intrinsic properties of the refractory. This technology circumvents the need to insert an isolated monolithic, stand-alone sensor into the refractory via an access port. This technological approach guarantees the integrity and the chemical stability of the materials used in the sensor fabrication within the harsh environment and does not introduce molten material (such as slag) penetration pathways within the refractory. One interesting and important aspect of this innovation is that these embedded sensors can be used to in situ monitoring processes such as chemical reactions and at the same time give information and a deeper understanding of the corrosion and erosion process of the refractory within the system. As stated above, the objective of our work is to develop high-temperature sensors composed of electroceramic materials that are chemically stable at high temperatures (750°-1500°C) and high pressures (up to 1000 psi) that can be used in monitoring corrosion and erosion process in refractory used in high energy systems. The high-temperature sensors investigated in this work were composed of various oxide composites directly embedded into the refractory oxides. The composites used for this work were synthesized by a mixed-oxide route. Metal oxides were inserted within a matrix material composed of refractory oxides (Al2O3, ZrO2, etc.). The physical and electrical properties were specifically manipulated by altering the level of percolation of the conductive species (metal oxides) within the refractory constituent (refractory oxide). Prior to the development of the high-temperature sensors, the oxides composites developed in this study were sintered up to 1600°C under oxidizing atmosphere in order to investigate densification, microstructural evolution, phase development, and their thermoelectrical performance as a function of the composition. The 4-point DC conductivity measurements were performed between 100°-1500°C. The sensors were fabricated from the composite materials by 3D-printing or screen-printing methods into the refractory brick during the consolidation process. An example of one of these embedded sensors consisted of an electroceramic-based thermocouple fabricated with two separate oxide composite compositions which were patterned to produce a couple within the interior of a refractory matrix. The thermocouple successfully displayed thermoelectric voltage trend (as a function of temperature), and the voltage was 220.0 mV around 1400 °C. Corrosion tests on the refractory embedded sensors were performed. To evaluate corrosion in the refractory brick an in-house glass composition was prepared and pressed into pellets and delivered into a pre-cut cavity in the brick. Corrosion experiments results showed the glass penetrated the brick over a 90 h period, and the penetration of the glass through the brick could be monitored by both an amperometric and voltametric based sensor. With this experiment, it was demonstrated that the embedded sensor could dynamically monitor the corrosion process.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2020

Electrochemically induced crystallization of amorphous materials in molten MgCl2: boron nitride and hard carbon

A novel and versatile strategy for the amorphous-to-crystalline transformation of boron nitride (BN) with the capability to control the degree of crystallization was developed through an electrochemical pathway using MgCl 2 at low temperature (750 °C). This procedure can be extended to the transformation of amorphous carbon to graphite, which significantly reduces the energy and cost, accelerates the synthesis process and could potentially replace industrial graphite synthesis globally. Therefore, the synthesized graphite exhibits much enhanced electrochemical performance at high charge–discharge rates (5C) compared to commercial synthetic graphite.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

X-ray diffraction from shock driven Sn microjets

Here, in situ x-ray diffraction was performed on shock-generated microjets composed of Sn and Sn–4Ag. Under low pressure drives (~21 GPa), a significant fraction of the jet volume was found to be in the β-Sn phase, and these crystallites were much smaller than the initial grain size of the material. Significant quantities of amorphous (molten) material were observed for higher drive pressures (~25–35 GPa). The extent of melting at these pressures was greater than would be predicted for uniaxial shock loading. Diffraction patterns from the Sn–4Ag alloy showed a peak that is consistent with the expected Ag 3 Sn intermetallic phase. This peak remained evident under drive conditions where the sample was otherwise fully amorphous. This indicates a slushy or a mixed phase of liquid Sn and solid Ag 3 Sn. Given the eutectic character of this alloy, this observation is attributed to a kinetic limitation on the dissolution of Ag 3 Sn. This implies that a much broader range of drive conditions will lead to mixed phase jets and ejecta than would be predicted from the equilibrium melt boundary of such alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Material Control and Accounting for Liquid-Fueled Molten Salt Reactors: Material Control and Holdup Considerations

The US Nuclear Regulatory Commission (NRC) will likely require license applicants for liquid-fueled molten salt reactors (MSRs) with circulating fuel to submit a nuclear material control and accounting (MC&A) plan or detailed MC&A program description for the facility. In liquid-fueled MSRs with special nuclear material (SNM) in bulk (i.e., not in discrete items) form and rapidly changing quantities due to fuel transmutation and depletion, using traditional nuclear material accounting methods with material balance evaluations is challenging. In reactors with changing inventories, these expected quantities of SNM must be calculated based on operational parameters. Reducing uncertainties on these expected quantities is challenging in the case of MSRs without decades of operational experience to verify and validate predictive computational codes. Moreover, many areas in MSRs are inaccessible because of high-temperature and high-radiation environments, making measurements challenging.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

Exploring Cr and molten salt interfacial interactions for molten salt applications

Molten salts play an important role in various energy-related applications such as high-temperature heat transfer fluids and reaction media. However, the extreme molten salt environment causes the degradation of materials, raising safety and sustainability challenges. A fundamental understanding of material–molten salt interfacial evolution is needed. This work studies the transformation of metallic Cr in molten 50/50 mol% KCl–MgCl 2 via multi-modal in situ synchrotron X-ray nano-tomography, diffraction and spectroscopy combined with density functional theory (DFT) and ab initio molecular dynamics (AIMD) simulations. Notably, in addition to the dissolution of Cr in the molten salt to form porous structures, a δ-A15 Cr phase was found to gradually form as a result of the metal–salt interaction. This phase change of Cr is associated with a change in the coordination environment of Cr at the interface. DFT and AIMD simulations provide a basis for understanding the enhanced stability of δ-A15 Cr vs. bcc Cr, by revealing their competitive phase thermodynamics at elevated temperatures and probing the interfacial behavior of the molten salt at relevant facets. This study provides critical insights into the morphological and chemical evolution of metal–molten salt interfaces. Finally, the combination of multimodal synchrotron analysis and atomic simulation also offers an opportunity to explore a broader range of systems critical to energy applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Simultaneous reaction and separation of chemicals

The reaction rate of hydrocarbon pyrolysis can be increased to produce solid carbon and hydrogen by the use of molten materials which have catalytic functionality to increase the rate of reaction and physical properties that facilitate the formation and contamination-free separation of the solid carbon. Processes, materials, reactor configurations, and conditions are disclosed whereby methane and other hydrocarbons can be decomposed at high reaction rates into hydrogen gas and carbon products without any carbon oxides in a single reaction step. The process also makes use of specific properties of selected materials with unique solubilities and/or wettability of products into (and/or by) the molten phase to facilitate generation of purified products and increased conversion in more general reactions.

McFarland, Eric W.↗