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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↗
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↗
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↗
DOE OSTI2020

Microstructural evolution of Mo-UO 2 cermets under high temperature hydrogen environments

Ceramic-metallic (cermet) materials show promise for use in nuclear thermal propulsion applications due to attractive thermophysical properties including high temperature stability and high thermal conductivity. In this work, molybdenum-uranium dioxide (Mo-UO 2 ) cermet fuel elements were fabricated by means of spark plasma sintering (SPS) and were subsequently exposed to hydrogen at high temperatures (2500 K). Mo-UO 2 samples pre- and post-exposure were characterized by means of optical microscopy, scanning electron microscopy, and X-ray diffraction (XRD). Microscopy analyses of the as-produced material displayed microscopic cracking on the interior of the spherical UO 2 fuel particles but confirmed that the fuel particles were fully encapsulated in the Mo matrix. The results further showed mass loss, macroscopic swelling, and cracking in the cermet samples which occurred during high temperature hydrogen testing. Nanoscale swelling was evidenced by XRD in the Mo matrix and UO 2 fuel structure due to the incorporation of defects and accompanied microstrain.

36 MATERIALS SCIENCE↗
DOE OSTI2025

A comparative review on cold sprayed cermet coatings and their applications in high temperature corrosion, oxidation and wear resistance

This review article explores the properties and bonding mechanisms specific to cold sprayed cermet coatings, highlighting its contrast with that of pure metals, and pure ceramics. The general cost structure of cold spraying is compared with other thermal spray techniques and the advantages are highlighted. Several cold sprayed cermet coatings with good corrosion, oxidation and wear resistance behavior in elevated temperatures show convincing potential for applications in power generation industries. The important factors that are attributed to producing highly functional cold sprayed cermet coatings are discussed. A strategic approach involving material, equipment, and application specific optimization of the cold spray process is currently relevant and of utmost importance to meet the coating requirements in several industrial applications.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Porous Permeable SHS Cermets Based on Iron and Aluminum Oxides

Optimal batch composition is developed for porous permeable SHS cermets that may be used in processing smokestack gases at factories and also auto exhaust emissions. The physicomechanical properties of the cermets are determined when different batch compositions are employed. The permissible range of vibrational frequencies when such cermets are used as filters is determined.

36 MATERIALS SCIENCE↗
DOE OSTI2019

High-throughput thermodynamic screening of carbide/refractory metal cermets for ultra-high temperature applications

Carbide/refractory metal cermets possess attractive combinations of thermal and mechanical properties for ultra-high temperature structural applications. Using a high-throughput computational thermodynamic approach, 16 carbide/refractory metal cermet systems were identified, out of 1808 possible combinations, that could be fabricated by the displacive compensation of porosity (DCP) method using molten copper alloys as infiltrators at 1300 °C. Experimental results for ZrC/W and ZrC/Mo, and other proposed systems in the literature provide a level of validation to this approach. We found that copper alloys are more suitable for DCP than aluminum alloys owing to the low melting temperature of copper alloys (e.g., Zr 2 Cu and Ti 2 Cu), and the minimal chemical reaction as well as very limited mutual solid solubility of copper with refractory metals. Our results show that high-throughput thermodynamics calculation is a robust approach for systematically and thoroughly identifying refractory metal cermets that are suitable for DCP.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Submersion criticality safety of tungsten-rhenium urania cermet fuel for space propulsion and power applications

Nuclear thermal rockets are the preferred propulsion technology for a manned mission to Mars, and tungsten–uranium oxide cermet fuels could provide significant performance and cost advantages for nuclear thermal rockets. A nuclear reactor intended for use in space must remain subcritical before and during launch, and must remain subcritical in launch abort scenarios where the reactor falls back to Earth and becomes submerged in terrestrial materials (including seawater, wet sand, or dry sand). Submersion increases reflection of neutrons and also thermalizes the neutron spectrum, which typically increases the reactivity of the core. This effect is typically very significant for compact, fast-spectrum reactors. This paper provides a submersion criticality safety analysis for a representative tungsten/uranium oxide fueled reactor with a range of fuel compositions. Each submersion case considers both the rhenium content in the matrix alloy and the uranium oxide volume fraction in the cermet. The inclusion of rhenium significantly improves the submersion criticality safety of the reactor. While increased uranium oxide content increases the reactivity of the core, it does not significantly affect the submersion behavior of the reactor. There is no significant difference in submersion behavior between reactors with rhenium distributed within the cermet matrix and reactors with a rhenium clad in the coolant channels. The combination of the flooding of the coolant channels in submersion scenarios and the presence of a significant amount of spectral shift absorbers (i.e. high rhenium concentration) further decreases reactivity for short reactor cores compared to longer cores.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2019

Mechanofusion for Improved Control of Cermet TPBAR Pellet Microstructure

Mechanofusion is an alternative fabrication technique that has the potential to advance cermet TPBAR pellets by producing LiAlO 2 -Zr core-shell powders that will provide tighter control of targeted microstructural characteristics such as the presence and thickness of Zr surrounding every LiAlO 2 particle in the cermet. Significantly enhanced microstructural control will translate to improved control of material properties and characteristics that affect the in-reactor performance of cermet TPBAR pellets. It was the intention of this work to demonstrate the efficacy of mechanofusion for producing precursor powders for TPBAR pellets, however materials procurement issues prevented this objective from being fully realized. In spite of these issues, in the short amount of time during which appropriate materials were available, it was demonstrated that mechanofusion does indeed have promise for producing the desired structures although the process yet requires optimization.

36 MATERIALS SCIENCE↗
DOE OSTI2019

IMPROVING INTERMEDIATE TEMPERATURE PERFORMANCE OF NI-YSZ CERMET ANODES FOR SOLID OXIDE FUEL CELLS BY INFILTRATION OF NICKEL NANOPARTICLES AND MIXED IONIC ELECTRONIC CONDUCTOR

Solid oxide fuel cells (SOFCs) are one of the most efficient and environment-friendly devices for electricity generation. One critical challenge of SOFC commercialization is high cell operating temperatures (800°C-1000°C), which lead to high material costs, high performance degradation rates, long start-up and shutdown times, and limited portable applications. Intermediate temperature (600°C-800°C) operation of SOFCs is limited by sluggish electrode reaction kinetics. The objective of this research is to improve intermediate temperature performance of commercially available Ni-YSZ cermet anode supported SOFCs by liquid infiltration of the anode. One effective method to improve kinetics of electrochemical reactions at the anode is to increase the density of reaction sites, which are known as the triple phase boundaries (TPBs). The porous Ni-YSZ cermet anodes were liquid infiltrated with Ni nanoparticles, leading to a four-fold increase in TPB density in the anode. The improved electrochemical performance of the infiltrated cells compared to the uninfiltrated cells highlights the effectiveness of anode infiltration in facilitating improved anode electrochemical reaction kinetics. However, the post-electrochemical testing characterization revealed that Ni nanoparticles were not stable due to Ni coarsening and were mostly isolated indicating that not all of the additional TPBs were fully utilized in electrochemical reactions due to the lack of an electronic pathway between the Ni nanoparticles. In order to improve microstructural stability of the infiltrated Ni nanoparticles, and to fully utilize the added TPBs, co-infiltration of Ni with a mixed ionic and electronic conductor (MIEC) was carried out. Two MIEC materials are chosen based on their chemical stability and conductivity in the anode operating environments; Gd 0.1 Ce 0.9 O 2-δ (GDC), a predominantly an ionic conductor, and La 0.6 Sr 0.3 Ni 0.15 Cr 0.85 O 3-δ (LSNC), a predominantly electronic conductor, and cells were successfully co-infiltrated to form Ni-GDC and Ni-LSNC nanostructures with the MIEC phases connecting the Ni nanoparticles. Stability tests demonstrated that both MIECs inhibited Ni nanoparticle coarsening. Electrochemical studies showed that Ni-GDC is the most effective for improved anode kinetics. A long-term (120 hours) electrochemical test indicated that infiltration of Ni-GDC into Ni-YSZ cermet anode effectively improves overall cell performance at intermediate temperatures and maintains the performance gain for a long period of time.

Lu, Yanchen↗