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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.
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.
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.
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.
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.
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.
Materials compatibility with hydrogen: hydrogen effects on materials laboratory (HEML).
Abstract not provided.
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.
Material Compatibility with Isothermal Pb-Li
Eutectic Pb-Li is a leading candidate for current fusion blanket concepts as a coolant. However, there is very little data about the compatibility of most materials with Pb-Li above 500 C where the dissolution rate of many conventional alloys increases rapidly. Current work is beginning to assess Pb-Li compatibility from 500 to 800 C using isothermal capsule experiments. Aluminide coatings hold some promise in protecting conventional Fe-base alloys at 600-700 C. However, there is a significant initial Al loss that has not been clearly explained. Furthermore, the reaction product with coated materials is LiAlO{sub 2} rather than Al{sub 2}O{sub 3} at 600 and 700 C. Even when pre-oxidized to form {alpha}-Al{sub 2}O{sub 3}, an alumina layer on FeCrAl transformed to LiAlO{sub 2} at 700 and 800 C. At 500 C, the preformed oxide partially transformed from alumina and some Li was detected in the oxide layer.
Integrated Data Collection Analysis (IDCA) Program - Mixing Procedures and Materials Compatibility
Three mixing procedures have been standardized for the IDCA proficiency test—solid-solid, solid-liquid, and liquid-liquid. Due to the variety of precursors used in formulating the materials for the test, these three mixing methods have been designed to address all combinations of materials. Hand mixing is recommended for quantities less than 10 grams and Jar Mill mixing is recommended for quantities over 10 grams. Consideration must also be given to the type of container used for the mixing due to the wide range of chemical reactivity of the precursors and mixtures. Eight web site sources from container and chemical manufacturers have been consulted. Compatible materials have been compiled as a resource for selecting containers made of materials stable to the mixtures. In addition, container materials used in practice by the participating laboratories are discussed. Consulting chemical compatibility tables is highly recommended for each operation by each individual engaged in testing the materials in this proficiency test.
Rapid Screening of Liquid Metal Wetting for a Materials Compatibility Library
Wetting behavior of molten metals on solid substrates is a critical phenomenon influencing numerous industrial applications, including welding, anti-corrosion coatings, and metal additive manufacturing (AM). In particular, molten metal jetting (MMJ), an emerging AM technology, requires that the molten metal remain pinned at the nozzle exit. Thus, each new metal requires a specific nozzle material to ensure consistent droplet ejection and deposition, making it important to rapidly identify the appropriate wetting combinations. However, traditional measurements of wetting angles require expensive equipment and only allow one combination of materials to be investigated at a time which can be time consuming. This work introduces a rapid screening method based on sessile droplet experiments to evaluate wetting profiles across multiple metal–substrate combinations simultaneously. This study investigates the wetting interactions of molten Al alloy (Al4008), Cu, and Sn on various ceramic and metal substrates to identify optimal material combinations for MMJ nozzle designs. Results demonstrate that Al4008 achieves wetting on ceramic substrates such as AlN, TiO 2 , and SiC, with varying mechanisms including chemical reactions and weak surface interactions. Additionally, theoretical predictions regarding miscibility gaps and melting point differences were verified for Cu and Sn on refractory metals like Mo and W. Findings from this study contribute to the establishment of a materials compatibility library, enabling the selection of wetting/non-wetting combinations for stable MMJ operation. This resource not only advances MMJ technologies but also provides valuable insights for broader applications such as welding, coating, and printed electronics.
High Pressure Hydrogen Materials Compatibility of Piezoelectric Films
Abstract: Hydrogen is being considered as a next-generation clean burning fuel. However, hydrogen has well known materials issues, including blistering and embrittlement in metals. Piezoelectric materials are used as actuators in hydrogen fuel technology. We present studies of materials compatibility of piezoelectric films in a high pressure hydrogen environment. Absorption of high pressure hydrogen was studied with Elastic Recoil Detection Analysis (ERDA) and Rutherford Back Scattering (RBS) in lead zirconate titanate (PZT) and barium titanate (BTO) thin films. Hydrogen surface degradation in the form of blistering and Pb mixing was also observed.
H2 Materials Compatibility of Low Cost, High Pressure, Polymer H2 Dispensing Hoses
NanoSonic was recently awarded a DOE Phase IIB SBIR program for the commercialization of an innovative metal-free polymer based H2 dispensing hose to make H2 an economically viable fuel alternative to gasoline. During the Phase I and Phase II base programs, NanoSonic's H2 hose demonstrated ultra-high hydrostatic burst strength values > 31,000 psi where failure occurred due to fitting slippage, rather than hose burst. Additionally, our hoses survived > 51,000 pressure impulse cycles at 12,000 psi over a thermal cycle of -40 °C to 85 °C. These hoses also failed due to fitting slippage. Thus, our Phase IIB program is centralized on the addition of a new fitting, polymer hose refinement, and validation of a complete hose and fitting system certified for use with H2. While NanoSonic has partnered with the National Renewable Energy Laboratory (NREL) to test our hose on their robotic H2 dispensing system, we are also seeking durability with the H2 environment at the molecular level. Here, NanoSonic proposes a CRADA with Pacific Northwest National Laboratory (PNNL), who has expertise in H2 polymer materials compatibility. Together, we will determine the lifetime of our H2 hose polymer and composite constituents via: 1) time-temperature superposition (TTS) studies via dynamic mechanical analysis (DMA) under H2, 2) friction and wear resistance under in situ H2 tribometry, and 3) multi-axis strain testing under cryogenic conditions. PNNL has the unique test equipment essential to gain this type of insight and lifetime prediction data. Importantly, the work conducted under the proposed CRADA will increase the safety and reliability of our H2 hoses while expanding the market for use of our low H2 permeation polymers and durable cryogenic composites to realize the H2@Scale objectives to reduce the cost of H2.
Materials compatibility for hydrogen service: standardized test methodology for qualification of materials .
Abstract not provided.
Materials compatibility and aging for flux and cleaner combinations
A materials study of high reliability electronics cleaning is presented here. In Phase 1, mixed type substrates underwent a condensed contaminants application to view a worst- case scenario for unremoved flux with cleaning agent residue for parts in a silicone oil filled environment. In Phase 2, fluxes applied to copper coupons and to printed wiring boards underwent gentle cleaning then accelerated aging in air at 65% humidity and 30 O C. Both sets were aged for 4 weeks. Contaminants were no-clean (ORL0), water soluble (ORH1 liquid and ORH0 paste), and rosin (RMA; ROL0) fluxes. Defluxing agents were water, solvents, and engineered aqueous defluxers. In the first phase, coupons had flux applied and heated, then were placed in vials of oil with a small amount of cleaning agent and additional coupons. In the second phase, pairs of copper coupons and PWB were hand soldered by application of each flux, using tin-lead solder in a strip across the coupon or a set of test components on the PWB. One of each pair was cleaned in each cleaning agent, the first with a typical clean, and the second with a brief clean. Ionic contamination residue was measured before accelerated aging. After aging, substrates were removed and a visual record of coupon damage made, from which a subjective rank was applied for comparison between the various flux and defluxer combinations; more corrosion equated to higher rank. The ORH1 water soluble flux resulted in the highest ranking in both phases, the RMA flux the least. For the first phase, in which flux and defluxer remained on coupons, the aqueous defluxers led to worse corrosion. The vapor phase cleaning agents resulted in the highest ranking in the second phase, in which there was no physical cleaning. Further study of cleaning and rinsing parameters will be required.
Material Compatibility with Regard to Hydrogen Transport
Oregon State University Materials Science Seminar, Corvallis, OR, June 1, 2023