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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 OSTI2020

Thermal diffusivity of irradiated tungsten and tungsten-rhenium alloys

The Japan-US PHENIX project irradiated tungsten materials in the RB-19J capsule experiment in the High Flux Isotope Reactor (HFIR). A gadolinium (Gd) shielding was used to absorb the thermal neutrons and reduce rhenium and osmium generation in tungsten. Pure tungsten and K-doped W-3% Re samples were irradiated at 532 – 662 °C to dose of 0.21-0.46 dpa, with the grain orientation perpendicular or parallel to the disk surface. Thermal diffusivity measurements were performed from 100 °C to 500 °C. Furthermore, additional measurements followed after annealing up to 900 °C. Irradiated pure tungsten specimens showed similar thermal diffusivity results compared with an unirradiated W-1% Re specimen in another study. The transmutation amount of Re was calculated to be about 0.52% for those specimens that showed good agreement with this study. Specimens irradiated in this study to different doses presented almost the same thermal diffusivity. Annealing up to 800 °C resulted in no recovery of thermal diffusivity. These results show that the contribution of crystalline defects to degradation of thermal diffusivity is quite limited. In addition, the thermal diffusivity of the irradiated specimens was getting close to that of the unirradiated specimens at elevated temperature.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Recycling and Reuse of Tungsten-Rhenium Refractory Alloy Powder for Additive Manufacturing (Quarterly Progress Report - 01 April 2023-30 June 2023)

Savannah River National Laboratory in partnership with 6K Inc is working on demonstrating laser and electron-beam powder bed additive manufacturing processes of W-24Re alloy and developing powder reconditioning (deoxidation) technology via plasma spheroidization and investigating the properties and performance of additively manufactured W-24Re components produced using both virgin and recycled powders.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Helium-implantation-induced lattice strains and defects in tungsten probed by X-ray micro-diffraction

Tungsten is the main candidate material for plasma-facing armour components in future fusion reactors. Bombardment with energetic fusion neutrons causes collision cascade damage and defect formation. Interaction of defects with helium, produced by transmutation and injected from the plasma, modifies defect retention and behaviour. Here we investigate the residual lattice strains caused by different doses of helium-ion-implantation into tungsten and tungsten-rhenium alloys. Energy and depth-resolved synchrotron X-ray micro-diffraction uniquely permits the measurement of lattice strain with sub-micron 3D spatial resolution and ~10 -4 strain sensitivity. Increase of helium dose from 300 appm to 3000 appm increases volumetric strain by only ~2.4 times, indicating that defect retention per injected helium is ~3 times higher at low helium doses. This suggests defect retention is not a simple function of implanted helium dose, but strongly depends on material composition and presence of impurities. Conversely, analysis of W-1 wt% Re alloy samples and of different crystal orientations shows that both the presence of rhenium, and crystal orientation, have a comparatively small effect on defect retention. These insights are key for the design of armour components in future reactors where it will be essential to account for irradiation-induced dimensional change when predicting component lifetime and performance.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Optimized Gen-II FeCrAl cladding production in large quantity for campaign testing

There are two major objectives in this report; (1) to optimize microstructure control of ATF FeCrAl alloys during tube drawing processes, and (2) to provide an update on the progress of ATF FeCrAl tube production via commercial manufacturers. Experimental efforts have been made to optimize the process parameters balancing the tube fabricability, especially for tube drawing processes, and microstructure control of the final tube products. Lab-scale sheet materials of Gen II FeCrAl alloys (Mo-containing and Nb-containing FeCrAl alloys) were used in the study, combined with a stepwise warm-rolling process and intermediate annealing, aiming to simulate the tube drawing process in a commercial tube manufacturer. The intermediate annealing at 650ºC for 1h was suggested for the tube-drawing process of Mo-containing FeCrAl alloys because it successfully softened the material by recovering the work hardening introduced through the rolling step, without inducing grain coarsening due to recrystallization. The final tube product is expected to have stabilized deformed microstructure providing the improved tensile properties with sufficient ductility. Optimization efforts on Nb-containing FeCrAl alloys focused on the effect of alloying additions and annealing conditions on the stability of deformed microstructure. Relationships between the second-phase precipitates (Fe 2 Nb-Laves phase) and microstructure stability are discussed. FeCrAl tube production through commercial tube manufacturers is currently in progress. Three different manufacturers, Century Tubes, Inc. (CTI), Rhenium Alloys, Inc. (RAI), and Superior Tube Company, Inc. (STC), are providing capabilities for cold-drawing, warm-drawing, and HPTR cold-pilgering, respectively. The first two companies are currently working on large quantity tube production (expected 250 ft length) of Gen I model FeCrAl alloy (B136Y3, at CTI) and Gen II (C35M4, at RAI), with the process parameters obtained from the experimental efforts. The expected delivery dates are at the end of July, 2016, and the middle of June, 2016, respectively. Tube production at STC would be the first attempt to apply cold-pilgering to the FeCrAl alloys. Communication has been initiated, and the materials have been machined for the cold-pilgering process.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Microstructure and Mechanical Properties of Friction Stir Welded Q235 Low-Carbon Steel

Three-millimeter-thick Q235 steel plates were friction stir welded using a tool made of tungsten-rhenium alloy in the present study. The microstructure and mechanical properties of welded joints at various traverse speeds from 50 to 150 mm/min were analyzed. It was demonstrated that traverse speed had great impacts on microstructure and mechanical properties of the joints. Phase transformation accompanied with recrystallization occurred during FSW process which resulted in different microstructures in the WNZ, and the grain size in other zones was significantly affected by traverse speed. The highest hardness was located in the nugget zone, while the lowest hardness was found in the heat-affected zone. The transverse tensile test suggested that all the joints showed slightly lower tensile strength than that of the base material, and the tensile strength increased with increasing traverse speed. All the joints fractured in the heat-affected zone with ductile fracture mode. The impact test showed that the impact toughness decreased with the increasing traverse speed and the impact fracture surface could be divided into shear lip zone and fibrous zone which showed a typical ductile fracture.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Informing ARC divertor design and plasma facing material selection through integrated modeling

This INFUSE 2023 project between UCLA and Commonwealth Fusion Systems used computer modeling to test whether tungsten materials can survive in CFS's ARC fusion reactor divertor. The team simulated plasma conditions and material responses, finding that tungsten-rhenium alloys resist grain growth better than pure tungsten, and that hydrogen buildup depends more on particle flux than temperature. The work helps CFS design durable plasma-facing components for their fusion power plant.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Recovery of Platinum Group Metals from Spent Catalysts Using Iron Chloride Vapor Treatment

The recovery of platinum group metals (PGMs) from spent automobile catalysts is a difficult process because of their relatively low contents in the scrap. In this study, to improve the efficiency of the existing recycling techniques, a novel physical concentration method involving treatment with FeCl{sub 2} vapor has been examined. The reactions occurring between typical catalyst components and FeCl{sub 2} vapor are discussed from the thermodynamic point of view, and the validity of the proposed technique was experimentally verified. The obtained results indicate that the vapor treatment at around 1200 K (927 °C) can effectively alloy PGMs (Pt, Pd, and Rh) with Fe, resulting in the formation of a ferromagnetic alloy. It was also confirmed that cordierite and alumina (the major catalyst components) remained unreacted after the vapor treatment, while ceria species were converted into oxychlorides. The samples simulating the automobile catalyst were also subjected to magnetic separation after the treatment with FeCl{sub 2} vapor; as a result, PGMs were successfully extracted and concentrated in the form of a magnetic powder. Thus, the FeCl{sub 2} vapor treatment followed by magnetic separation can be utilized for recovering PGMs directly from spent catalysts as an effective pretreatment for the currently used recycling methods.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Structure and Phase Composition of Heat-Resistant Ni–Al–Co Alloy After Annealing and Creep

The paper presents research into the structure and phase composition of Ni–Al–Co alloy modified by rhenium (~3 аt.%) alloying. Observations are carried out using the transmission electron microscopy. The initial state of the alloy is the state after the directional crystallization. The alloy is further subjected to 900°С annealing during 1143 h. Creep tests are additionally carried out for this alloy at the same temperature and time and 400 MPa load. It is shown that FCC disordered γ- and ordered γ′-phases are major in all alloy states. Secondary phases are found to be σ-phase, χ-phase, Laves and AlRe{sub 2} phases. Experiments show that the high temperature annealing changes the phase composition of the alloy. Thus, the amount of the ordered γ′-phase increases, while that of disordered γ-phase decreases. During the creep process, the amount of the former reduces and the amount of the latter increases. The annealing process modifies the phase composition in secondary phases. It is found that the structural modification caused by the creep process differs from that caused by the annealing process. Thus, the creep-induced modification of the cuboid structure in γ′-phase is stronger than due to annealing. Dislocations are observed in γ- and γ′-phases in all states of the alloy. During the annealing process, the dislocation density in γ-phase is higher than in γ′-phase, and vice versa during the creep process. The experiments show that the behavior of the dislocation structures is different during the annealing and creep processes.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Identifying rhenium substitute candidate multiprincipal-element alloys from electronic structure and thermodynamic criteria

While rhenium has proven to be an ideal material in fast-cycling high-temperature applications such as rocket nozzles, its prohibitive cost limits its continued use and motivates a search for viable cost-effective substitutes. We show that a simple design principle that trades off average valence electron count and cost considerations proves helpful in identifying a promising pool of candidate substitute alloys: The Mo–Ru–Ta–W quaternary system. We demonstrate how this picture can be combined with a computational thermodynamic model of phase stability, based on high-throughput ab initio calculations, to further narrow down the search and deliver alloys that maintain rhenium’s desirable hcp crystal structure. Here, this thermodynamic model is validated with comparisons to known binary phase diagram sections and corroborated by experimental synthesis and structural characterization demonstrating multiprinciple-element hcp solid-solution samples selected from a promising composition range.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Effect of alloying by lanthanum and high rhenium superalloys on the basis of Ni-Al-Cr on the structure and phase composition

This paper presents transmission and scanning electronic microscope investigations of Ni-Al-Cr superalloy alloyed with additional Re and La elements. This superalloy is obtained by the directional solidification method and subsequently is subjected to two-stage high-temperature annealing: 1) at T = 1150°C, the test time is 1 hour; 2) at T = 1100°C, the testing time is 1430 hours. It was found that the γ- and γ′-phases are the main phases in the two states on the basis of fcc lattice. Where γ is the disordered fcc solid solution and γ′-phase is the main phase with an ordered arrangement of atoms having the L1{sub 2} superstructure. It is shown that such additional elements as Re and La result in the formation of new phases in Ni-Al-Cr accompanied by considerable modifications of quasi-cuboid structure in its γ′-phase. The phase composition and morphology of the phases are studied.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Materials synthesis at terapascal static pressures

Theoretical modelling predicts very unusual structures and properties of materials at extreme pressure and temperature conditions. Hitherto, their synthesis and investigation above 200 gigapascals have been hindered both by the technical complexity of ultrahigh-pressure experiments and by the absence of relevant in situ methods of materials analysis. Here we report on a methodology developed to enable experiments at static compression in the terapascal regime with laser heating. We apply this method to realize pressures of about 600 and 900 gigapascals in a laser-heated double-stage diamond anvil cell, producing a rhenium–nitrogen alloy and achieving the synthesis of rhenium nitride Re 7 N 3 —which, as our theoretical analysis shows, is only stable under extreme compression. Full chemical and structural characterization of the materials, realized using synchrotron single-crystal X-ray diffraction on microcrystals in situ, demonstrates the capabilities of the methodology to extend high-pressure crystallography to the terapascal regime.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Electrodeposition of Tungsten using Hydrotropic Agents

The current work sought to electrodeposit tungsten from water-based solutions. The work’s initial hypothesis was that methoxide reducing agents could be used to generate urea anions that could enable tungsten electrodeposition. Unfortunately, this hypothesis was found to be incorrect. However, the work led to the understanding that chemical reducing agents not only enable the electrodeposition of refractory metals like rhenium from water-based solutions, but that the key to plating tungsten in the future involves chemical reduction followed by stabilization with proper ligands. The work resulted in a manuscript under review at Inorganic Chemistry Communications on the discovered of L-histidine as a suitable reducing agent from rhenium electrodeposition. Rhenium-tungsten alloys with 4% tungsten were deposited. A technical advance was filed for the rhenium chemistry and parts were delivered to an internal Sandia customer that used the chemistry.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2018

Rhenium-Doped and Stabilized MoS 2 Atomic Layers with Basal-Plane Catalytic Activity

The development of stable and efficient hydrogen evolution reaction (HER) catalysts is essential for the production of hydrogen as a clean energy resource. A combination of experiment and theory demonstrates that the normally inert basal planes of 2D layers of MoS 2 can be made highly catalytically active for the HER when alloyed with rhenium (Re). The presence of Re at the ≈50% level converts the material to a stable distorted tetragonal (DT) structure that shows enhanced HER activity as compared to most of the MoS 2 -based catalysts reported in the literature. More importantly, this new alloy catalyst shows much better stability over time and cycling than lithiated 1T-MoS 2 . Density functional theory calculations find that the role of Re is only to stabilize the DT structure, while catalysis occurs primarily in local Mo-rich DT configurations, where the HER catalytic activity is very close to that in Pt. The study provides a new strategy to improve the overall HER performance of MoS 2 -based materials via chemical doping.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Elemental Characterization of Neutron-Irradiated Tungsten Using the GD-OES Technique

In reactor-relevant fusion divertor conditions, tungsten (W) will be used as an armor material due to its excellent thermal properties. It will be exposed to impurities from numerous sources, including ion implantation and mixing, neutron transmutation, low-Z plasma-facing-component (PFC) redeposition and codeposition of deuterium and tritium fuel, and trapped helium bubbles. The impurity plasma material–interaction effects are a concern because they can cause gradual degradation of the material and of plasma performance due to dust formation, fuel retention, and even changes to the thermal and mechanical properties of the W armor. It is crucial to measure the amount of impurities in W, and the glow discharge–optical emission spectroscopy (GD-OES) technique is exceptionally well suited for analysis of irradiated samples. GD-OES can measure a sample’s elemental composition by sputtering the surface of the sample, ionizing the eroded material, and measuring the optical emission of the excited atoms. In order for the GD-OES technique to be applied to neutron-irradiated tungsten samples, a mounting system for miniature samples was designed. The sample mounting and centering procedure was successful in measuring the depth distribution of control W and W alloy sample elemental concentrations. These control depth spectra will be used as elemental references for postirradiated samples. The residence time of surface layers was measured, a comparison of signals from different anodes was completed, and the influence of initial surface roughness or nonuniformity was understood. The depth distribution of an arc-welded W-0.4% rhenium (Re) alloy was measured to have a stable Re signal that was distributed evenly in the W matrix. Here, the methods developed here will allow for quantification of impurities and transmutation amounts in neutron-irradiated W. GD-OES is a powerful tool but requires calibration and careful optimization of the parameters to obtain meaningful results.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

High-pressure high-temperature synthesis of NdRe 2

In this study, we report the synthesis of a new cubic neodymium-rhenium metallic alloy NdRe 2 through the utilization of high pressure and laser heating in a diamond anvil cell. NdRe 2 crystallizes in the Fd$\overline{3}$m space group with a lattice parameter equal to 7.486 (2) Å and Z = 8 at 24 (1) GPa and 2,200 (100) K. It was studied using high-pressure single-crystal X-ray diffraction. The compound crystallizes in the cubic MgCu 2 structure type. Its successful synthesis further proves that high-pressure high-temperature conditions can be used to obtain alloys holding a Laves phase structure. Ab initio calculations were done to predict the mechanical properties of the material. We also discuss the usage of extreme conditions to synthesize and study materials present in the nuclear waste.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2015

Pt 3 Re alloy nanoparticles as electrocatalysts for the oxygen reduction reaction

Development of renewable energy technologies requires advanced catalysts for efficient electrical-chemical energy conversion reactions. Here in this paper, we report the study of Pt-Re alloy nanoparticles as an electrocatalyst for the oxygen reduction reaction (ORR). An organic solution approach is developed to synthesize monodisperse and homogeneous Pt 3 Re alloy nanoparticles. Electrochemical studies show that these nanoparticles exhibit an improvement factor of 4 in catalytic activity for the ORR compared to commercial Pt catalysts of similar particle sizes. Fundamental understanding of the structure-property relationship is established by combining material characterization using X-ray spectroscopy and atomically resolved electron microscopy, as well as Density Functional Theory (DFT) calculations. Lastly, our work revealed that an electronic modification of the surface properties of Pt by subsurface Re (ligand effect) accounts for the catalytic enhancement.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Strengthening of tungsten by coherent rhenium precipitates formed during low fluence irradiation

Experimental data show that the accumulation of rhenium and osmium from transmutation reactions severely affect the microstructural evolution and property degradation of tungsten-based materials under neutron irradiation. Theory and modeling have confirmed that Re atom transport in W is by irradiation-produced migrating self-interstitial atoms. With this diffusion mode in operation, a specific microstructure evolution is realized when at relatively low neutron fluence the Re-rich precipitates are formed, while the void and interstitial loop population development is suppressed, affecting the mechanical properties. Here, this research shows the effect of small coherent Re-rich precipitates on the dislocation glide under stress, investigated using the molecular dynamics approach with empirical interatomic potentials. The results are compared with an earlier simulation of void hardening in W. It is demonstrated that small coherent Re-rich precipitates of less than 6 nm diameter represent relatively weak obstacles for moving edge dislocations. The implication of these results on the interpretation of experimental results is discussed.

36 MATERIALS SCIENCE↗