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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 OSTI2016

Interfacial engineering of solution-processed Ni nanochain-SiO{sub x} (x < 2) cermets towards thermodynamically stable, anti-oxidation solar selective absorbers

Cermet solar thermal selective absorber coatings are an important component of high-efficiency concentrated solar power (CSP) receivers. The oxidation of the metal nanoparticles in cermet solar absorbers is a great challenge for vacuum-free operation. Recently, we have demonstrated that oxidation is kinetically retarded in solution processed, high-optical-performance Ni nanochain-SiO{sub x} cermet system compared to conventional Ni-Al{sub 2}O{sub 3} system when annealed in air at 450–600 °C for several hours. However, for long-term, high-temperature applications in CSP systems, thermodynamically stable antioxidation behavior is highly desirable, which requires new mechanisms beyond kinetically reducing the oxidation rate. Towards this goal, in this paper, we demonstrate that pre-operation annealing of Ni nanochain-SiO{sub x} cermets at 900 °C in N{sub 2} forms the thermodynamically stable orthorhombic phase of NiSi at the Ni/SiO{sub x} interfaces, leading to self-terminated oxidation at 550 °C in air due to this interfacial engineering. In contrast, pre-operation annealing at a lower temperature of 750 °C in N{sub 2} (as conducted in our previous work) cannot achieve interfacial NiSi formation directly, and further annealing in air at 450–600 °C for >4 h only leads to the formation of the less stable (metastable) hexagonal phase of NiSi. Therefore, the high-temperature pre-operation annealing is critical to form the desirable orthorhombic phase of NiSi at Ni/SiO{sub x} interfaces towards thermodynamically stable antioxidation behavior. Remarkably, with this improved interfacial engineering, the oxidation of 80-nm-diameter Ni nanochain-SiO{sub x} saturates after annealing at 550 °C in air for 12 h. Additional annealing at 550 °C in air for as long as 20 h (i.e., 32 h air annealing at >550 °C in total) has almost no further impact on the structural or optical properties of the coatings, the latter being very sensitive to any interfacial changes due to the localized surface plasmon resonances of the metal nanostructures. This phenomenon holds true for Ni nanoparticle diameter down to 40 nm in Ni-SiO{sub x} system, where the optical response remains stable for 53 h at 550 °C in air. The oxidation vs. time curve also shows saturation behavior deviating from the kinetic Deal-Grove oxidation model. These results strongly suggest a promising approach to thermodynamically stable, anti-oxidation Ni/SiO{sub x} cermet absorbers via interfacial engineering.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2014

Enhanced Thermal Stability of W-Ni-Al 2 O 3 Cermet-Based Spectrally Selective Solar Absorbers with Tungsten Infrared Reflectors

Solar thermal technologies such as solar hot water and concentrated solar power trough systems rely on spectrally selective solar absorbers. These solar absorbers are designed to efficiently absorb the sunlight while suppressing re-emission of infrared radiation at elevated temperatures. Efforts for the development of such solar absorbers must not only be devoted to their spectral selectivity but also to their thermal stability for high temperature applications. In this work, selective solar absorbers based on two cermet layers are fabricated on mechanically polished stainless steel substrates using a magnetron sputtering technique. The targeted operating temperature is 500–600 °C. A detrimental change in the morphology, phase, and optical properties is observed if the cermet layers are deposited on a stainless steel substrate with a thin nickel adhesion layer, which is due to the diffusion of iron atoms from the stainless steel into the cermet layer forming a FeWO 4 phase. In order to improve thermal stability and reduce the infrared emittance, tungsten is found to be a good candidate for the infrared reflector layer due to its excellent thermal stability and low infrared emittance. Lastly, a stable solar absorptance of ≈0.90 is demonstrated, with a total hemispherical emittance of 0.15 at 500 °C.

14 SOLAR ENERGY↗
DOE OSTI2020

Fabrication of UN-Mo CERMET Nuclear Fuel Using Advanced Manufacturing Techniques

Ceramic-metallic nuclear fuels are a candidate fuel for nuclear thermal propulsion systems due to their high heat transport properties, which are necessary in very high-temperature environments. The conventional fabrication of uranium nitride–molybdenum fuel has been thoroughly studied in the past, but modern manufacturing techniques have presented a unique opportunity for further development within this field. This work demonstrates the use of advanced manufacturing techniques to produce nuclear fuel pellets composed of uranium nitride microspheres encased in a molybdenum matrix. Binder jetting is used to print molybdenum disks that are filled with uranium nitride microspheres and afterward sintered using spark plasma sintering. Two fuel pellets were fabricated to demonstrate the methodology and to provide a baseline analysis of the effects of temperature and pressure processing conditions. Characterization of the sintered fuel pellets includes detailed microstructural analysis and thermal conductivity measurements.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2019

Behavior of yttria-stabilized zirconia (YSZ) during laser direct energy deposition of an Inconel 625-YSZ cermet

Thermal barrier coatings (TBC) are regularly used today to protect and extend the service life of several superalloys which are extensively used in high temperature applications. The existing TBCs are typically between 0.1 to 0.5 mm in thickness, are deposited on metal substrates using plasma spray or electron beam vapor deposition, and can reduce temperatures at the substrate surface by up to 300 °C. For greater temperature reductions there is a need for thicker TBCs. The building of thick TBCs has to date been stymied by poor adhesion, and cracking during deposition. It has been suggested that a functionally graded approach may reduce the residual stresses which result in these defects. To date there have been few reports on the deposition of ceramic or cermet coatings using laser AM and none have reported on the phase stability of ceramic particles post-deposition. This article is a first report on the phase stability of ceramic particles following the compositional segregation of elements during deposition using a powder feed additive manufacturing process. Functionally graded (FG), thick TBCs (>3 mm) consisting of Inconel 625 (IN625) and yttria-partially stabilized zirconia (8YSZ) were deposited on an A516 steel substrate via laser direct energy deposition (LDED). Good interfaces were observed between the bond coat (BC) and first cermet layer and between the graded cermet layers. However, cermet layers deposited with 10 wt.% or more YSZ developed a thin layer of YSZ on the surface. The thin layer of YSZ greatly hindered additional deposition of new cermet layers. In cermet layers that did exhibit good interfaces, fine, re-solidified, YSZ particles were homogenously distributed within the Inconel 625 matrix. The YSZ particles exhibited a tetragonal lattice structure and were depleted of yttrium. In contrast, the thin YSZ layer formed on a cermet surface showed no yttrium depletion.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1975

Effect of magnesium oxide content on oxidation behavior of some superalloy-base cermets

The effect of increasing magnesium oxide (MgO) content on the cyclic oxidation resistance of hot-pressed cermets of MgO in NiCrAlY, MgO in Hoskins-875, MgO in Inconel-702, and MgO in Hastelloy-X was investigated. The cermets with magnesium oxide levels of 5, 10, 20, and 40 vol percent were examined. The cyclic oxidation behavior of these cermets at 1100 and 1200 C in still air was determined by a thermogravimetric method supplemented by X-ray diffraction analysis and light and electron microscopy. In all instances, MgO prevented grain growth in the metallic phase. No evidence of oxidation along interphase boundaries was detected. Cermets of MgO in NiCrAlY and MgO in Hoskins-875 were superior to cermets of MgO in Inconel-702 and MgO in Hastelloy-X. Their oxidation resistance was degraded only when the MgO content was 40 vol percent. The oxidation behavior of MgO-in-Inconel-702 powder cermets containing 5- and 10-vol percent MgO was approximately similar to that of pure Inconel-702 compacts. The 20- and 40-vol percent MgO content reduced the oxidation resistance of MgO-in-Inconel-702 powder cermets relative to that of pure Inconel-702.

Zaplatynsky, I.↗
DOE OSTI2024

Ceramic–Metal (Cermet) Composites: A Review of Key Properties and Synthesis Methods Focused on Nuclear Waste Immobilization

Here this paper reviews key properties, applications, and examples of ceramic-metal composites (cermets), and metal matrix composites (MMC) with emphasis on their applicability as waste forms for immobilizing nuclear waste. While the literature is mature for vitrified and cementitious radioactive waste forms, cermet materials have not received adequate attention as potential candidates for immobilizing nuclear waste. To promulgate this effort, this review connects cermet and MMC design, such as hardened tools, with the chemistry of radioactive waste streams. A discussion on certification and qualification standards for cermet waste forms, literature gaps, and “how-to” sections on cermet processing techniques. Key parameters discussed include thermal conductivity, chemical durability, and waste loading, as well as examples for metal-containing waste forms. As cermet waste forms gain momentum within the community, this review paper aims ensure the end-of-life nuclear fuel cycle is addressed from a materials and waste disposition perspective.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS2005

Fabrication of High Temperature Cermet Materials for Nuclear Thermal Propulsion

Processing techniques are being developed to fabricate refractory metal and ceramic cermet materials for Nuclear Thermal Propulsion (NTP). Significant advances have been made in the area of high-temperature cermet fuel processing since RoverNERVA. Cermet materials offer several advantages such as retention of fission products and fuels, thermal shock resistance, hydrogen compatibility, high conductivity, and high strength. Recent NASA h d e d research has demonstrated the net shape fabrication of W-Re-HfC and other refractory metal and ceramic components that are similar to UN/W-Re cermet fuels. This effort is focused on basic research and characterization to identify the most promising compositions and processing techniques. A particular emphasis is being placed on low cost processes to fabricate near net shape parts of practical size. Several processing methods including Vacuum Plasma Spray (VPS) and conventional PM processes are being evaluated to fabricate material property samples and components. Surrogate W-Re/ZrN cermet fuel materials are being used to develop processing techniques for both coated and uncoated ceramic particles. After process optimization, depleted uranium-based cermets will be fabricated and tested to evaluate mechanical, thermal, and hot H2 erosion properties. This paper provides details on the current results of the project.

Hickman, Robert↗
NASA NTRS2004

Solar Absorptance of Cermet Coatings Evaluated

Cermet coatings, molecular mixtures of metal and ceramic, are being considered for the heat inlet surface of solar Stirling convertors. In this application, the key role of the cermet coating is to absorb as much of the incident solar energy as possible. To achieve this objective, the cermet coating has a high solar absorptance value. Cermet coatings are manufactured utilizing sputter deposition, and many different metal and ceramic combinations can be created. The ability to mix metal and ceramic at the atomic level offers the opportunity to tailor the composition, and hence, the optical properties of these coatings. The NASA Glenn Research Center has prepared and characterized a wide variety of cermet coatings utilizing different metals deposited in an aluminum oxide ceramic matrix. In addition, the atomic oxygen durability of these coatings has been evaluated.

Jaworske, Donald A.↗
NASA NTRS2014

Affordable Development and Optimization of CERMET Fuels for NTP Ground Testing

CERMET fuel materials for Nuclear Thermal Propulsion (NTP) are currently being developed at NASA's Marshall Space Flight Center. The work is part of NASA's Advanced Space Exploration Systems Nuclear Cryogenic Propulsion Stage (NCPS) Project. The goal of the FY12-14 project is to address critical NTP technology challenges and programmatic issues to establish confidence in the affordability and viability of an NTP system. A key enabling technology for an NCPS system is the fabrication of a stable high temperature nuclear fuel form. Although much of the technology was demonstrated during previous programs, there are currently no qualified fuel materials or processes. The work at MSFC is focused on developing critical materials and process technologies for manufacturing robust, full-scale CERMET fuels. Prototypical samples are being fabricated and tested in flowing hot hydrogen to understand processing and performance relationships. As part of this initial demonstration task, a final full scale element test will be performed to validate robust designs. The next phase of the project will focus on continued development and optimization of the fuel materials to enable future ground testing. The purpose of this paper is to provide a detailed overview of the CERMET fuel materials development plan. The overall CERMET fuel development path is shown in Figure 2. The activities begin prior to ATP for a ground reactor or engine system test and include materials and process optimization, hot hydrogen screening, material property testing, and irradiation testing. The goal of the development is to increase the maturity of the fuel form and reduce risk. One of the main accomplishmens of the current AES FY12-14 project was to develop dedicated laboratories at MSFC for the fabrication and testing of full length fuel elements. This capability will enable affordable, near term development and optimization of the CERMET fuels for future ground testing. Figure 2 provides a timeline of the development and optimization tasks for the AES FY15-17 follow on program.

Hickman, Robert R.↗
DOE OSTI2014

Structural state scale-dependent physical characteristics and endurance of cermet composite for cutting metal

A structural-phase state developed on the surface of a TiC/Ni–Cr–Al cermet alloy under superfast heating and cooling produced by pulse electron beam melting has been presented. The effect of the surface’s structural state multimodality on the temperature dependencies of the friction and endurance of the cermet tool in cutting metal has been investigated. The high-energy flux treatment of subsurface layers by electron beam pulses in argon-containing gas discharge plasma serves to improve the endurance of metal cutting tools manifold (by a factor of 6), to reduce the friction via precipitation of secondary 200 nm carbides in binder interlayers. It is possible to improve the cermet tool endurance for cutting metal by a factor of 10–12 by irradiating the cermet in a reactive nitrogen-containing atmosphere with the ensuing precipitation of nanosize 50 nm AlN particles in the binder interlayers.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2016

High performance mid-temperature selective absorber based on titanium oxides cermet deposited by direct current reactive sputtering of a single titanium target

This paper reports the design and fabrication of a new double cermet-based low-mid temperature solar selective absorber based on TiO x cermet layers, which were deposited with a single Ti target by varying O 2 partial pressure in sputtering chamber as reactive gas. High metal volume fraction cermet 1 and low metal volume fraction cermet 2 were deposited with O 2 partial pressure of 0.15 mTorr and 0.25 mTorr, respectively, with direct current power density of 6.58 W cm -2 . The complex refractive indices from ellipsometry were used to design solar selective absorber. The reflectance, thermal stability, and morphology were studied in absorbers on Cu and stainless steel. The effect of TiO 2 and SiO 2 as anti-reflective coating layers was investigated. Finally, the absorber on Cu substrate has high absorptance of 90.8% and low emittance of 4.9% (100 °C), and changed to 96.0% and 6.6%, respectively, after annealing at 300 °C for 4 days.

42 ENGINEERING↗
NASA NTRS1966

Basic Behavior and Properties of W-UO2 Cermets

Thermal cycling studies on cermets prepared from tungsten and UO2 powder mixtures and cermets prepared using tungsten coated UO2 particles are discussed. The cermets were tested in hydrogen at high temperatures to determine the effects of temperature, thermal cycling, and hydrogen pressure. Basic mechanism studies of tungsten­-UO2 interactions in thermally cycled cermets are also described.

Baker, R. J.↗
NASA NTRS1976

Oxidation behavior of nickel-chromium-aluminum-yttrium - Magnesium oxide and nickel-chromium-aluminum-yttrium - zirconate type of cermets

The 1100 and 1200 C cyclic oxidation resistance of dense Ni-Cr-Al-Y - MgO, Ni-Cr-Al-Y - CaZrO3, Ni-Cr-Al-Y - SrZrO3, Ni-Cr-Al-Y - MgZro3 cermets and a 70 percent dense Ni-Cr-Al-Y developmental material was determined. The cermets contained 60 and 50 volume percent of Ni-Cr-Al-Y which formed a matrix with the oxide particles imbedded in it. The cermets containing MgO were superior to cermets based on zirconates and to the porous Ni-Cr-Al-Y material.

Zaplatynsky, I.↗
NASA NTRS1991

A cermet fuel reactor for nuclear thermal propulsion

Work on the cermet fuel reactor done in the 1960's by General Electric (GE) and the Argonne National Laboratory (ANL) that had as its goal the development of systems that could be used for nuclear rocket propulsion as well as closed cycle propulsion system designs for ship propulsion, space nuclear propulsion, and other propulsion systems is reviewed. It is concluded that the work done in the 1960's has demonstrated that we can have excellent thermal and mechanical performance with cermet fuel. Thousands of hours of testing were performed on the cermet fuel at both GE and AGL, including very rapid transients and some radiation performance history. We conclude that there are no feasibility issues with cermet fuel. What is needed is reactivation of existing technology and qualification testing of a specific fuel form. We believe this can be done with a minimum development risk.

Kruger, Gordon↗