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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

Hydrogen Compatible Materials Workshop

This report serves as the proceedings of the Hydrogen Compatible Materials Workshop held virtually by Sandia National Laboratories on December 2-3, 2020. The purpose of the workshop was to assemble subject matter experts at Sandia and its national laboratory partners within the U.S. Department of Energy's (DOE) Hydrogen Materials Compatibility (H-Mat) Consortium with public and private stakeholders in the research, development and deployment of hydrogen technologies to discuss the topic of hydrogen compatible materials. This workshop was designed to build on past events and current research and development (R&D) efforts to develop a forward-looking vision that identifies gaps and challenges for the next decade. In particular, the workshop organizers sought to expand their understanding of hydrogen compatible materials needs for power, manufacturing and other industrial uses to enable deeper impact and widespread use of hydrogen while continuing to address open questions in hydrogen-powered transportation of concern to Original Equipment Manufacturers, hydrogen producers, materials & component suppliers and other private entities. The workshop was primarily organized as a series of panel-led discussions on the topics of hydrogen-enabled transportation, heating and power, and industrial uses. Each panel consisted of 2-3 subject matter experts who relayed their perspectives on a set of framing questions developed to facilitate discussion by the broader group of workshop participants. By the workshop's conclusion, the participants identified and prioritized a list of technical challenges for each panel topic where further R&D is warranted.

08 HYDROGEN↗
NASA NTRS1990

Hydrocarbon-fuel/combustion-chamber-liner materials compatibility

Results of material compatibility experiments using hydrocarbon fuels in contact with copper-based combustion chamber liner materials are presented. Mil-Spec RP-1, n- dodecane, propane, and methane fuels were tested in contact with OFHC, NASA-Z, and ZrCu coppers. Two distinct test methods were employed. Static tests, in which copper coupons were exposed to fuel for long durations at constant temperature and pressure, provided compatibility data in a precisely controlled environment. Dynamic tests, using the Aerojet Carbothermal Test Facility, provided fuel and copper compatibility data under realistic booster engine service conditions. Tests were conducted using very pure grades of each fuel and fuels to which a contaminant, e.g., ethylene or methyl mercaptan, was added to define the role played by fuel impurities. Conclusions are reached as to degradation mechanisms and effects, methods for the elimination of these mechanisms, selection of copper alloy combustion chamber liners, and hydrocarbon fuel purchase specifications.

Gage, Mark L.↗
DOE OSTI2022

Material Compatibility of 3D Printed Polymer Composites with Low GWP Refrigerants

The recent development of 3D printing brings numerous opportunities to develop polymer heat exchangers with desired configurations and allows access to the new complex engineering design for better performance. To be used in the HVAC&R system, the compatibility of these materials to refrigerants needs to be thoroughly investigated and understood. This study tested the material compatibility of the printed polymer composites according to the ASHRAE Guideline 38 using metal pressure vessels. These printed parts were tested with R-134A, R-1234YF, R-1234ZE, R-1233ZD(E), and 32-3 MAF POE (10 wt.%) was used as the lubricants. The change in volume, mass, hardness, and mechanical properties was studied in detail. Different compatibility of the composites with refrigerants was observed when the composition of the composite changed. After exposure to refrigerants, the morphological and thermal properties were studied with the scanning electron microscope, thermogravimetric analysis, and differential scanning calorimetry to further reveal the influence of these refrigerants.

Li, Kai↗
DOE OSTI2021

Conceptual design of HFIR irradiation experiment for material compatibility study on liquid Sn divertor

Liquid Sn is one of the promising coolants for liquid surface divertor concept of fusion reactors. However, the compatibility between liquid Sn and structural materials is an important issue that has to be addressed, because liquid Sn is extremely corrosive to steels at high temperatures. The corrosion may be mitigated when a protective Al2O 3 layer is formed on the surface of alumina forming steels. However, the effect of neutron irradiation on the integrity of protective layer is not made clear so far. Japan and US joint research project “FRONTIER” started in 2019 to investigate the material compatibility under neutron irradiation. The purpose of the present study is to develop the conceptual design of the irradiation test capsule which enables material compatibility tests for the alumina forming steels - liquid metal systems under neutron irradiation in the High Flux Isotope Reactor at Oak Ridge National Laboratory, TN, USA. The three dimensional drawing of capsule structure was then developed. The validity of the material selections for the capsule design was investigated by means of corrosion tests of SiC, Si3N4, Ti, and Mo in liquid Sn at 773 K for 262 hr.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
NASA NTRS1976

Propellant material compatibility program and results

The effects of long-term (up to 10 years) contact of inert materials with earth-storable propellants were studied for the purpose of designing chemical propulsion system components that can be used for current as well as future planetary spacecraft. The primary experimental work, and results to date are reported. Investigations include the following propellants: hydrazine, hydrazine-hydrazine nitrate blends, monomethyl-hydrazine, and nitrogen tetroxide. Materials include: aluminum alloys, corrosion-resistant steels, and titanium alloys. More than 700 test specimen capsules were placed in long-term storage testing at 43 C in the special material compatibility facility. Material ratings relative to the 10-year requirement have been assigned.

Toth, L. R.↗
DOE OSTI2015

Nanoalloy Printed and Pulse-Laser Sintered Flexible Sensor Devices with Enhanced Stability and Materials Compatibility

While conformal and wearable devices have become one of the most desired formats for printable electronics, it is challenging to establish a scalable process that produces stable conductive patterns but also uses substrates compatible with widely available wearable materials. Here, we describe findings of an investigation of a nanoalloy ink printed and pulsed laser sintered conductive patterns as flexible functional devices with enhanced stability and materials compatibility. While nanoparticle inks are desired for printable electronics, almost all existing nanoparticle inks are based on single-metal component, which, as an electronic element, is limited by its inherent stabilities of the metal such as propensity of metal oxidation and mobility of metal ions, especially in sintering processes. The work here has demonstrated the first example in exploiting plasmonic coupling of nanoalloys and pulsed-laser energy with controllable thermal penetration. The experimental and theoretical results have revealed clear correlation between the pulsed laser parameters and the nanoalloy structural characteristics. The superior performance of the resulting flexible sensor device, upon imparting nanostructured sensing materials, for detecting volatile organic compounds has significant implications to developing stable and wearable sensors for monitoring environmental pollutants and breath biomarkers. This simple “nanoalloy printing 'laser sintering' nanostructure printing” process is entirely general to many different sensor devices and nanostructured sensing materials, enabling the ability to easily construct sophisticated sensor array.

Environmental Molecular Sciences Laboratory↗
NASA NTRS1972

Material Compatibility with Space Storable Propellants. Design Guidebook

An important consideration in the design of spacecraft for interplanetary missions is the compatibility of storage materials with the propellants. Serious problems can arise because many propellants are either extremely reactive or subject to catalytic decomposition, making the selection of proper materials of construction for propellant containment and control a critical requirement for the long-life applications. To aid in selecting materials and designing and evaluating various propulsion subsystems, available information on the compatibility of spacecraft materials with propellants of interest was compiled from literature searches and personal contacts. The compatibility of both metals and nonmetals with hydrazine, monomethyl hydrazine, nitrated hydrazine, and diborance fuels and nitrogen tetroxide, fluorine, oxygen difluoride, and Flox oxidizers was surveyed. These fuels and oxidizers encompass the wide variety of problems encountered in propellant storage. As such, they present worst case situations of the propellant affecting the material and the material affecting the propellant. This includes material attack, propellant decomposition, and the formation of clogging materials.

Uney, P. E.↗
DOE OSTI2014

Design and realization of one-dimensional double hetero-structure photonic crystals for infrared-radar stealth-compatible materials applications

In this paper, a new type one-dimensional (1D) double hetero-structure composite photonic crystal (CPC) for infrared-radar stealth-compatible materials applications was proposed and studied numerically and experimentally. First, based on transfer matrix method of thin-film optical theory, the propagation characteristics of the proposed structure comprising a stack of different alternating micrometer-thick layers of germanium and zinc sulfide were investigated numerically. Calculation results exhibit that this 1D single hetero-structure PC could achieve a flat high reflectivity gradually with increasing the number of the alternating media layers in a single broadband range. Then, based on principles of distributed Bragg reflector micro-cavity, a 1D double hetero-structure CPC comprising four PCs with thickness of 0.797 μm, 0.592 μm, 1.480 μm, and 2.114 μm, respectively, was proposed. Calculation results exhibit that this CPC could achieve a high reflectance of greater than 0.99 in the wavelength ranges of 3–5 μm and 8–14 μm and agreed well with experiment. Further experiments exhibit that the infrared emissivity of the proposed CPC is as low as 0.073 and 0.042 in the wavelength ranges of 3–5 μm and 8–12 μm, respectively. In addition, the proposed CPC can be used to construct infrared-radar stealth-compatible materials due to its high transmittance in radar wave band.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2021

Joint LLNL & SNL Material Compatibility Study Commences

The fundamental goal of the W80-4 Life Extension Program (LEP) is the design and production of a safe and reliable system. Ensuring long-term viability and chemical compatibility of the materials in the warhead is paramount to its success. To that end, the material and aging compatibility team, which includes researchers from Lawrence Livermore and Sandia National Laboratories (SNL), has launched the LEP’s most comprehensive compatibility test to date.

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

A Materials Compatibility and Thermal Stability Analysis of Common Hydrocarbon Fuels

A materials compatibility and thermal stability investigation was conducted using five common liquid hydrocarbon fuels and two structural materials. The tests were performed at the NASA Glenn Research Center Heated Tube Facility under environmental conditions similar to those encountered in regeneratively cooled rocket engines. Scanning-electron microscopic analysis in conjunction with energy dispersive spectroscopy (EDS) was utilized to characterize the condition of the tube inner wall surface and any carbon deposition or corrosion that was formed during selected runs. Results show that the carbon deposition process in stainless steel tubes was relatively insensitive to fuel type or test condition. The deposition rates were comparable for all fuels and none of the stainless steel test pieces showed any signs of corrosion. For tests conducted with copper tubing, the sulfur content of the fuel had a significant impact on both the condition of the tube wall and carbon deposition rates. Carbon deposition rates for the lowest sulfur fuels (2 ppm) were slightly higher than those recorded in the stainless steel tubes with no corrosion observed on the inner wall surface. For slightly higher sulfur content (25 ppm) fuels, nodules that intruded into the flow area were observed to form on the inner wall surface. These nodules induced moderate tube pressure drop increases. The highest sulfur content fuels (400 ppm) produced extensive wall pitting and dendritic copper sulfide growth that was continuous along the entire tube wall surface. The result of this tube degradation was the inability to maintain flow rate due to rapidly increasing test section pressure drops. Accompanying this corrosion were carbon deposition rates an order of magnitude greater than those observed in comparable stainless steel tests. The results of this investigation indicate that trace impurities in fuels (i.e. sulfur) can significantly impact the carbon deposition process and produce unacceptable corrosion levels in copper based structural materials.

Meyer, M. L.↗
DOE OSTI2018

Study of Material Compatibility for a Thermal Energy Storage System with Phase Change Material

The suitability of stainless steel 316L and Inconel 625 for use in a latent heat thermal energy storage (TES) system was investigated. A NaCl–NaF eutectic mixture with a melting temperature of 680 °C was used as the phase change material (PCM). Containers were filled with the PCM prior to heating to 750 °C, then examined after 100 and 2500 h of high-temperature exposure by analyzing the material surface and cross-section areas. A small amount of corrosion was present in both samples after 100 h. Neither sample suffered significant damage after 2500 h. The undesirable inter-granular grain boundary attack found in SS316L samples was in the order of 1–2 µm in depth. On Inconel 625 sample surface, an oxide complex formed, resisting material dissolution into the PCM. The surface morphology of tested samples remained largely unchanged after 2500 h, but the corrosion pattern changed from an initially localized corrosion penetration to a more uniform type. After 2500 h, the corrosion depth of Inconel 625 remained at roughly 1–2 µm, indicating that the corrosion rate decelerated. Both materials demonstrated good compatibility with the chosen NaF–NaCl eutectic salt, but the low corrosion activity in Inconel 625 samples shows a performance advantage for long term operation.

25 ENERGY STORAGE↗
NASA NTRS2024

NASA Engineering and Safety Center Technical Bulletin No. 24-01: Material Compatibility of Common Aerospace Metals in MMH/MON-3

The NESC evaluated material compatibility of some common aerospace metals in monomethylhydrazine (MMH) and nitrogen tetroxide (MON-3). Previous work had identified a lack of quantitative compatibility data for nickel alloy 718, 300 series stainless steel, and titanium Ti-6Al-4V in MMH and MON-3 to support the use of zero-failure-tolerant, thin-walled pressure barriers in these propellants. Static (i.e., not flowing) general corrosion and electrochemistry testing was conducted, evaluating varied processing forms and heat treatment of the metals, water content of propellant, and exposure duration. Corrosion-rate data for all tested product forms, fluids, and durations were on the order of 1 x 10 –6 inch per year rather than the previously documented “less than 1 x 10 –3 inch per year”. The majority of the corrosion products were seen in the first 20 days of exposure, with an overall corrosion rate decreasing with time due to the increased divisor (time). It is therefore recommended that corrosion testing be performed at multiple short-term durations to inform the need for longer-duration testing.

Heather K Hickman↗