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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Development of Refractory Alloys and Refractory Coatings for Advanced Nuclear Reactors

The next generation of nuclear reactors will benefit from materials that enable operation at higher temperatures (>500°C), higher irradiation doses (up to 200 displacements per atom (dpa)), and the use of more corrosive and reactive coolants. This work package represents the first experimental steps towards a longer-term effort to develop refractory materials for nuclear energy applications which will enable operation under these conditions. Specifically, this work package focuses on additive manufacturing of refractories as both a refractory liner coating deposited onto the interior surface of a metallic tubular backbone and as bulk refractory alloys. During fiscal year 23 (FY23), several refractory metal coating systems and bulk alloys were examined and selected using a decision criteria matrix. The refractory metal coating systems included molybdenum, tungsten, and zirconium as refractory coatings on backbones of either carbon-carbon (C/C) or silicon carbide-silicon carbide (SiC/SiC) ceramic matrix composites. The bulk refractory alloys included C-103, WTa, and WNiFe as bulk alloys. During FY24 additional bulk refractory alloys and metallic backbones were evaluated using the decision criteria matrix based on input from the AMMT leadership team. These included 316 SS and 316H SS for the metallic backbones and Mo-La, Ta, and Nb1Zr as bulk refractory alloys. The primary focus for the FY24 effort was placed on establishing the capabilities to deposit refractory coatings based on the results of the scoring in the decision criteria matrix and finalizing the additively manufactured TZM studies which were incorporated into the AMMT program from the microreactor program. Further efforts were dedicated to establishing the capabilities to additively manufacture down-selected bulk refractory alloys.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

The Path towards Plasma Facing Components: A Review of State-of-the-art in W-Based Refractory High-Entropy Alloys

Developing advanced materials for plasma-facing components (PFCs) in fusion reactors is a crucial aspect for achieving sustained energy production. Tungsten (W) - based refractory high-entropy alloys (RHEAs) have emerged as promising candidates due to their superior radiation tolerance and high-temperature strength. This review paper will focus on recent advancements in W-based RHEA research, particularly emphasizing the key role of modelling using machine learning (ML) in the stage of discovery by predicting properties for each composition and expediting the identification of optimal RHEA compositions with desired properties. Additionally, the application of additive manufacturing (AM) techniques for fabricating W-based RHEAs is explored, highlighting their advantages for rapid prototyping and multi-compositional sample production in a high throughput manner. The review critically evaluates the current understanding of mechanical properties relevant to PFC applications, including high-temperature strength and ductility. Furthermore, the radiation tolerance of W-based RHEAs under irradiated conditions is discussed. Finally, the validity of current AM-manufactured W-based RHEAs as PFC materials is assessed, and key challenges and opportunities for future research are identified. This review aims to provide a comprehensive overview of W-based RHEAs for fusion applications and their potential to guide the development and validation of advanced refractory high entropy alloys.

Hatler, Caleb [University of Wisconsin-Madison]↗
DOE OSTI2019

Interaction of Iron with Alumina Refractory Under Flash Ironmaking Conditions

A novel flash ironmaking technology (FIT) based on the direct reduction of iron ore concentrate by a reducing gas such as hydrogen, natural gas, or coal gas has been developed at the University of Utah. A proper choice of refractories is expected to play an important role in the development of FIT and its scale-up. In this work, the interaction of iron with alumina refractory under flash ironmaking conditions has been investigated. A thermodynamic basis for the interaction phenomena has been developed by considering the Fe-Al-O system, and a kinetic model based on solid-state diffusion is proposed to describe the growth of the hercynite (FeAl{sub 2}O{sub 4}) spinel formed as a result of the interaction between Fe, O (from H{sub 2}O and CO{sub 2}), and Al{sub 2}O{sub 3}. Experiments were conducted with Fe powders and pure Al{sub 2}O{sub 3} in the temperature range 1200 to 1500 °C under gas atmospheres relevant to flash ironmaking, and the reacted samples were analyzed using XRD, SEM-EDX, and EPMA techniques. The analyses of reacted samples confirmed the formation of the hercynite (FeAl{sub 2}O{sub 4}) spinel phase and the thickness of the FeAl{sub 2}O{sub 4} spinel as measured using elemental line scans in SEM-EDX and EPMA varied in the range of 0.5 to 1.3 mm. Results showed that the proposed model suitably describes the growth of the hercynite spinel layer, which obeyed the parabolic rate law at all temperatures. The parabolic rate constants were obtained and the diffusion-controlled growth of the FeAl{sub 2}O{sub 4} layer strongly depended on temperature. Furthermore, using the kinetic model, an expression for the effective diffusivity ( (D{sub eff})-bar ) was obtained and its values at the experimental temperatures were determined. The solid-state diffusion was an activated process, as expected, with an activation energy value of 231 kJ/mol.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Computational exploration of biomedical HfNbTaTiZr and Hf 0.5 Nb 0.5 Ta 0.5 Ti 1.5 Zr refractory high-entropy alloys

Refractory high entropy alloys (RHEAs) have been proven to be a potential candidate in the biomedical field due to their balanced mechanical properties and biocompatible composition. Recent experimental findings show that RHEAs like HfNbTaTiZr and Hf 0.5 Nb 0.5 Ta 0.5 Ti 1.5 Zr have good mechanical properties such as high polarization and wear resistance than others which establish them as potential materials for biomedical application. In this work, we performed first-principles density functional theory calculations on the mechanical and thermal properties of HfNbTaTiZr and Hf 0.5 Nb 0.5 Ta 0.5 Ti 1.5 Zr. The predicted lattice constant, density, Young's modulus, and Vickers hardness are consistent with the available experimental report, which verifies the accuracy of the applied model. The thermal coefficient of linear expansion of both RHEAs has been investigated by utilizing the Debye theory. The present methods could be applied to study other future RHEAs on exploration of their physical properties.

36 MATERIALS SCIENCE↗
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 OSTI2025

Corrosion Testing of Refractory inContact with Molten Glasses Designed for Waste Vitrification - VSL Touchpoint Matrix Glasses

It is known that the predictive life of the refractory ceramic liner of nuclear waste glass melters is conservative, as demonstrated by performance of these materials such as in the Defense Waste Processing Facility (DWPF). The motivation for this task is to maximize the useful life of the melters that will be operated at the Waste Treatment and Immobilization Plant (WTP), which will in turn minimize procurement and disposal costs and melter outage times, as well as to identify maximum loadings in the waste glass of those species that corrode melter components. This task was initiated jointly with Pacific Northwest National Laboratory (PNNL) with the objective to develop a methodology and model to enable more accurate prediction of refractory service life under prototypic conditions from laboratory-scale material corrosion tests. Refractory corrosion is generally reported as physical material loss, measured in units of distance (e.g., inch) or as physical material loss rate, measured in units of distance per time (e.g., inch/day). In post-operational melters, the refractory corrosion is measured directly, sometimes reported as corrosion depth. Crucible tests are used in the laboratory to accelerate the refractory corrosion to facilitate a meaningful measurement in a commensurate amount of time. Crucible tests are particularly useful in understanding refractory corrosion across a large glass composition space, where operational testing would be prohibitive. Some of the critical parameters that are known to influence refractory corrosion by molten glass in a crucible test are temperature, system redox, molten salt phases, glass chemistry, and test duration. The majority of data collected for Monofrax® K-3 (hereafter referred to as K-3) corrosion is from crucible tests, but a small amount comes directly from scaled and production melters. Crucible test data has been collected under varying conditions, whereas data collected from operational melters is relatively fewer and represents conditions specific to the melter campaign. The result is that the published data can be grouped and analyzed in multiple ways, not all of which are readily comparable. The Standard Test Method for Isothermal Corrosion Resistance of Refractories to Molten Glass (ASTM C621) outlines the general guidelines used across industry. That method describes a sealed, static test in which the surface area of the refractory coupon and the volume of glass are fixed. A significant portion of the crucible data pertaining to nuclear waste glasses has been collected in a modified configuration; the most notable differences being the surface area of the refractory coupon to volume of the glass and use of a method for bubbling the melt. To our knowledge, the influence of those parameters on the refractory corrosion has not been quantified. In this work, it was determined that static tests and bubbled tests would be performed. Savannah River National Laboratory (SRNL) was tasked with setting up and performing static testing while PNNL was tasked with setting up and performing bubbled testing. Initial activities were performed to establish laboratory methods that reproduce data comparable to existing data sets of K-3 refractory corrosion by low activity waste (LAW) and high-level waste (HLW) glass compositions. Later activities were focused on refining the test parameters to establish a standard test practice to be used between Laboratories and collecting additional data to be used in the enhanced waste glass model development. This document serves primarily to convey the refractory loss measurement results from corrosion testing of K-3 refractory with waste glass compositions developed for use in the WTP melters. The data will be used in the enhanced property/composition models being developed for waste glass vitrification and melter operations.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2018

Interactions of Alumina-Based and Magnesia-Based Refractories with Iron Melts and Slags: A Review

A novel flash ironmaking technology (FIT) based on the direct reduction of iron ore concentrate with a reductant gas (such as hydrogen, natural gas, coal gas, or a combination thereof) in a flash furnace is being developed at the University of Utah. This technology which is undergoing large-scale laboratory testing aims at overcoming the limitations of blast furnace ironmaking by bypassing the problematic pelletization/sintering and cokemaking steps.[1–5] Refractory selection is expected to play an important step in the development of FIT and its proposed scale-up. For nominating an appropriate refractory for the FIT, understanding the interactions of candidate refractories with iron/iron oxide and slags under H{sub 2}/CO/CO{sub 2}/H{sub 2}O environments is necessary. This work is undertaken to review the existing literature on the interactions of important refractories with iron melts and relevant slags with an emphasis on two of the most commonly used refractories in ironmaking and steelmaking applications: the alumina-based refractories (used widely in blast furnace operations) and the magnesia-based refractories (used extensively in primary as well as secondary steelmaking). First, a comprehensive review on the interactions of alumina-based refractories with iron melts and slags has been done. Next the existing literature on the interactions of magnesia-based refractories with iron melts and relevant slags has been reviewed. Summaries have been included after each section and sub-section along with comments and critical insights from the authors. Finally, in the concluding remarks the differences in operating conditions between existing iron and steelmaking practices and the novel FIT have been highlighted. On the basis of these differences, it has been argued that the results and conclusions available from previous studies on refractory–metal–slag interactions are of little significance to flash ironmaking. Thus, there exists a need to carry out laboratory experiments for evaluating refractory performance in flash ironmaking under conditions relevant to the current process (FIT).

36 MATERIALS SCIENCE↗