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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 OSTI2021

Multielectrode Array Sensors to Enable Long-Duration Corrosion Monitoring and Control of Concentrating Solar Power Systems

Molten mixtures of MgCl2-KCl-NaCl are promising heat transfer fluid (HTF) candidates for the next generation of concentrating solar power systems (Gen3 CSP), because of their low cost, high decomposition temperature, and favorable heat transfer characteristics. However, if the chemistry of the salts is not properly controlled, molten chlorides can cause corrosion of high-temperature metal alloys, such as Inconel (R), in CSP systems. Here we demonstrate a corrosion monitoring system that can be used to monitor the health of the structural alloys over long durations. The monitoring system includes a multielectrode array voltammetry sensor that measures the redox potential of molten MgCl2-KCl-NaCl mixture as well as the presence of corrosion products and impurities. The sensors have been successfully operated in static molten salt environments for long durations, and are capable of detecting corrosion products, such as Cr2+ and Fe2+, quantitatively at low concentrations (i.e., approximately 100 ppm) with less than 4% error.

Concentrated solar power↗
DOE OSTI2021

Pressure-Driven Fiber-Optic Sensor for Online Corrosion Monitoring

For many industrial applications, corrosion is a life-limiting phenomenon and therefore requires careful consideration and rigorous experimental testing before structural materials can be reliably deployed, particularly in harsh chemical environments. The traditional approach to measuring corrosion requires exposing many samples to the intended environment and then extracting them individually at discrete intervals for postexposure characterization. This approach does not provide a high degree of temporal resolution, nor does it provide any real-time information regarding dynamic changes in corrosion rates. Additionally, developing an online corrosion monitor capable of surviving harsh chemical environments could provide valuable information regarding the structural health of components and changing process conditions that could accelerate corrosion. To this end, a corrosion sensor was developed based on a pressure-driven Fabry-Pérot cavity (FPC). This sensor uses a pressure control system to internally pressurize the FPC formed between the sensor’s housing and a metal-embedded singlemode optical fiber. Simultaneous measurement of the change in FPC length using low-coherence interferometry and the applied pressure enables the calculation of the relative changes in the sensor’s diaphragm thickness due to corrosion on its outer surface. Measurements were made in situ while actively corroding the sensor and were validated against surveillance specimens that were corroded simultaneously. The uncertainties in the measured corrosion were analyzed using error propagation of the uncertainties in the measured pressures and displacements and were found to be <1% of the initial diaphragm thickness.

42 ENGINEERING↗
DOE OSTI2025

Passive Wireless Sensors for Realtime Temperature and Corrosion Monitoring of Coal Boiler Components Under Flexible Operation (Final Technical Report)

Researchers at West Virginia University (WVU) propose to demonstrate inexpensive wireless, high-temperature sensors for real-time monitoring of the temperature and corrosion of metal components, which are commonly used in coal-fired boilers. This study presents the development of cost-effective wireless high-temperature sensors for real-time temperature and corrosion monitoring in coal-fired boilers' metal components. The focus is on fabricating and evaluating chipless radio-frequency identification (RFID) sensors capable of operating between 25-1300 ºC. Efforts were directed towards designing passive RFID sensor and interrogator antenna with a broad frequency range, optimizing a microstrip patch antenna sensor integrated into a "peel-and-stick" format for efficient application to various metal specimens without altering their geometry. Additionally, this research aimed to assess the sensor responses under accelerated high-temperature conditions, correlating corrosion and cracking mechanisms with sensor data. An investigation of through-wall data acquisition techniques was also planned, facilitating unobtrusive monitoring of sensor responses housed within metal enclosures. Ultimately, this work sought to establish a robust passive wireless sensor system for the continuous health monitoring of metal components in operational settings, thereby contributing to enhanced safety and efficiency in coal-fired power plants.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2025

Fe Coated Optical Fiber for Distributed Corrosion Monitoring in Soil and Aqueous Environment

Natural gas pipeline corrosion represents a substantial cost and safety concern during normal operations. Effective monitoring of corrosion is important to detect and mitigate pipeline risks before corrosion-related catastrophic events happen. Here, we describe the use of Fe-coated optical fiber sensors (OFS) for distributed corrosion monitoring where Fe acts as a corrosion proxy. By using an optical backscatterring reflectometer (OBR), corrosion was monitored based on the increase in backscattered intensity amplitude of the light being passed as Fe undergoes corrosion. The Fe-coated OFSs were prepared with a film thickness between 25-225 nm by an electroless plating approach and corroded by a CO2-saturated acidic electrolyte. The corrosion rate was approximately 2.5 mm/yr for Fe with a film thickness of 30 nm and increased with film thickness. Backscattering-based corrosion rates were supported by visible light transmission measurements, which have been previously demonstrated. Additionally, a correlation between the intermittent transmission and residual Fe film thickness during corrosion of Fe was established. Corrosion was measurable out to > 100 m which is a significant improvement over our previous work showing corrosion sensing at < 10 m. The corrosion sensor was also tested in soil at >1 ft depth. Fe-coated OFS was loaded into a Draka cable which provides mechanical support during fiber deployment and installation into either acidified soil, top-soil, or sandy soil.

aqueous environment↗
DOE OSTI2025

Fe-Coated Optical Fiber for Distributed Corrosion Monitoring in Soil and Aqueous Environment

Natural gas pipeline corrosion represents a substantial cost and safety concern during normal operations. The effective and real-time monitoring of corrosion is important to detect and mitigate pipeline risks before corrosion-related catastrophic events happen. Here, we describe the use of iron (Fe) coated optical fiber sensors (OFS) for distributed corrosion monitoring where Fe acts as a corrosion proxy. By using an optical backscattering reflectometer (OBR), corrosion was monitored based on the increase in the backscattered intensity amplitude of the light being passed as Fe underwent corrosion. The Fe-coated OFSs were prepared with a film thickness between 25–225 nanometers (nm) by an electroless plating approach and corroded by a carbon dioxide (CO2)-saturated acidic electrolyte. The corrosion rate (CR) was approximately 2.5 millimeters (mm)/year for Fe with a film thickness of 30 nm and increased with film thickness. Backscattering-based CRs were supported by visible light transmission measurements, which have been previously demonstrated. Additionally, a correlation between the intermittent transmission and residual Fe film thickness during the corrosion of Fe was established. The corrosion sensor was also tested in soil at > 1 foot depth. Fe-coated OFS was loaded into a Draka cable, which provides mechanical support during fiber deployment and installation into either acidified soil, top-soil, or sandy soil (50/50).

corrosion↗
DOE OSTI2025

Fe-Coated Optical Fiber for Distributed Corrosion Monitoring in Soil and Aqueous Environments

Natural gas pipeline corrosion represents a substantial cost and safety concern during normal operations. The effective and real-time monitoring of corrosion is important to detect and mitigate pipeline risks before corrosion-related catastrophic events happen. Here, we describe the use of iron (Fe) coated optical fiber sensors (OFS) for distributed corrosion monitoring where Fe acts as a corrosion proxy. By using an optical backscattering reflectometer (OBR), corrosion was monitored based on the increase in the backscattered intensity amplitude of the light being passed as Fe underwent corrosion. The Fe-coated OFSs were prepared with a film thickness between 25–225 nanometers (nm) by an electroless plating approach and corroded by a carbon dioxide (CO2)-saturated acidic electrolyte. The corrosion rate (CR) was approximately 2.5 millimeters (mm)/year for Fe with a film thickness of 30 nm and increased with film thickness. Backscattering-based CRs were supported by visible light transmission measurements, which have been previously demonstrated. Additionally, a correlation between the intermittent transmission and residual Fe film thickness during the corrosion of Fe was established. The corrosion was measurable out to > 100 meters (m), which is a significant improvement over our previous work, which showed corrosion sensing at < 10 m. The corrosion sensor was also tested in soil at > 1 foot depth.

corrosion↗
DOE OSTI2025

Fe-Coated Optical Fiber for Distributed Corrosion Monitoring in Soil and Aqueous Environments

Natural gas pipeline corrosion represents a substantial cost and safety concern during normal operations. The effective and real-time monitoring of corrosion is important to detect and mitigate pipeline risks before corrosion-related catastrophic events happen. Here, we describe the use of iron (Fe) coated optical fiber sensors (OFS) for distributed corrosion monitoring where Fe acts as a corrosion proxy. By using an optical backscattering reflectometer (OBR), corrosion was monitored based on the increase in the backscattered intensity amplitude of the light being passed as Fe underwent corrosion. The Fe-coated OFSs were prepared with a film thickness between 25–225 nanometers (nm) by an electroless plating approach and corroded by a carbon dioxide (CO2)-saturated acidic electrolyte. The corrosion rate (CR) was approximately 2.5 millimeters (mm)/year for Fe with a film thickness of 30 nm and increased with film thickness. Backscattering-based CRs were supported by visible light transmission measurements, which have been previously demonstrated. Additionally, a correlation between the intermittent transmission and residual Fe film thickness during the corrosion of Fe was established. The corrosion was measurable out to > 100 meters (m), which is a significant improvement over our previous work, which showed corrosion sensing at < 10 m. The corrosion sensor was also tested in soil at > 1 foot depth.

aqueous environment↗
NASA NTRS2002

Tracking the harmonic response of magnetically-soft sensors for wireless temperature, stress, and corrosive monitoring

This paper describes the application of magnetically-soft ribbon-like sensors for measurement of temperature and stress, as well as corrosive monitoring, based upon changes in the amplitudes of the higher-order harmonics generated by the sensors in response to a magnetic interrogation signal. The sensors operate independently of mass loading, and so can be placed or rigidly embedded inside nonmetallic, opaque structures such as concrete or plastic. The passive harmonic-based sensor is remotely monitored through a single coplanar interrogation and detection coil. Effects due to the relative location of the sensor are eliminated by tracking harmonic amplitude ratios, thereby, enabling wide area monitoring. The wireless, passive, mass loading independent nature of the described sensor platform makes it ideally suited for long-term structural monitoring applications, such as measurement of temperature and stress inside concrete structures. A theoretical model is presented to explain the origin and behavior of the higher-order harmonics in response to temperature and stress. c2002 Elsevier Science B.V. All rights reserved.

Non-NASA Center↗
DOE OSTI2021

Fe Thin Film-Coated Optics for Corrosion Monitoring: Optical and Electrochemical Studies

Corrosion proxy materials integrated with an optical sensing platform enable a real-time optical corrosion sensor for natural gas pipelines to prevent methane leaks and catastrophic events. Effects of CO 2 , pH, and film thickness on corrosion of Fe thin films (25, 50, 100 nm) were studied using optical and electrochemical methods in 3.5%wt. NaCl solutions at 30 °C. An increase in light transmission (T%) corresponded to corrosion of Fe thin films. CO 2 accelerated corrosion of Fe thin films due to the lower pH and the promoted corrosion reactions, resulting in a faster increase of T% than without CO 2 or at higher pH. While the corrosion rate increased with increasing film thickness, electrochemical corrosion of Fe thin films was in good agreement with that of bulk carbon steel, verifying that Fe thin films can serve as a representative corrosion proxy when integrated with the optical sensing platform.

36 MATERIALS SCIENCE↗
DOE OSTI2023

High Temperature Electrochemical Sensors for In-Situ Corrosion Monitoring in Coal-Based Power Generation Boilers

In this project, we successfully achieved the goals we proposed: 1. optimization and development of electrochemical sensor, 2. sensor construction and package, 3. sensor testing @Longview Power Plant and data analysis, 4. lab-scale sensor optimization and corrosion database development, 5. electrochemical and corrosion monitoring validation and 6. TEA.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2024

Near-Field Passive Wireless Sensor for High-Temperature Metal Corrosion Monitoring

This work focuses on the fabrication and evaluation of a passive wireless sensor for the monitoring of the temperature and corrosion of a metal material at high temperatures. An inductor–capacitor (LC) resonator sensor was fabricated through the screen printing of Ag-based inks on dense polycrystalline Al 2 O 3 substrates. The LC design was modeled using the ANSYS HFSS modeling package, with the LC passive wireless sensors operating at frequencies from 70 to 100 MHz. The wireless response of the LC was interrogated and received by a radio frequency signal generator and spectrum analyzer at temperatures from 50 to 800 °C in real time. The corrosion kinetics of the Cu 110 was characterized through thermogravimetric (TGA) analysis and microscopy images, and the oxide thickness growth was then correlated to the wireless sensor signal under isothermal conditions at 800 °C. The results showed that the wireless signal was consistent with the corrosion kinetics and temperature, indicating that these two characteristics can be further deconvoluted in the future. In addition, the sensor also showed a magnitude- and frequency-dependent response to crack/spallation events in the oxide corrosion layer, permitting the in situ wireless identification of these catastrophic events on the metal surface at high temperatures.

36 MATERIALS SCIENCE↗