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NETL’s metallurgists and materials scientists are responsible for developing affordable, high-performance alloys to enable numerous energy and industrial applications. This includes alloys with increased temperature capabilities that can enable highly efficient advanced energy systems, alloys for aerospace and defense applications, and a world leading biomedical alloy for coronary stents through a cost reimbursement agreement with an industrial partner. NETL utilizes an integrated computational materials engineering approach, which combines computational and experimental methods for translating materials science concepts into practical technologies. Key to this strategy are targeted experiments that evaluate performance in realistic service conditions and demonstrate manufacturing at scales and by methods that readily translate to industrial practice. NETL conducts research into a wide range of alloys including aluminum, high-conductivity copper, steels, superalloys, refractory alloys, and high-entropy alloys. NETL’s alloy development capability is anchored by its substantial ingot metallurgy manufacturing facilities (vacuum induction melting, vacuum arc remelting, and electro-slag remelting capabilities) that are unique within the national laboratory complex and the nation. Current research is focusing on affordable alloys and materials with improved resistance to hydrogen to enhance the safety, reliability and resiliency of hydrogen production from carbonaceous sources with carbon capture, transport in pipelines, and large-scale storage, as well as the utilization of hydrogen for power generation.

Materials Performance: Corrosion & Oxidation, Hydrogen Resistance

Corrosion, oxidation and hydrogen embrittlement have caused catastrophic failures of metallic components in many applications. Understanding a material’s response to environmental factors is critical for improving the reliability of systems and developing new corrosion resistant alloys and corrosion protection strategies. The Corrosion and Electrochemistry Lab (CEL) and related facilities are used to quantify and understand materials degradation in extreme service conditions. CEL has electronic potentiostats/galvanostatsmeters for conducting electrochemical experiments to measure corrosion rates using different electrochemical methods, for predicting susceptibility to pitting corrosion by determining pitting potential, and for determining conditions for corrosion protection. NETL also has test beds for assessing corrosion and oxidation at elevated temperatures and pressures. Current research focuses on materials performance in hydrogen environments; hydrogen-containing fuels and hydrogen combustion products; assessing materials, coatings and liners; and electrochemical sensor performance for applications in natural gas, hydrogen and CO2 pipelines.

Materials Performance: Mechanical Behavior

Scientists and engineers utilize the Mechanical Testing Laboratory to determine the mechanical behavior and performance of advanced materials under temperatures and pressures commonly associated with fossil energy systems. The focus of this work is to develop novel materials with enhanced performance characteristics. The laboratory is equipped to test a material’s ability to withstand cyclical mechanical loads for many cycles and resulting crack growth behavior of materials at temperatures up to 1200° C. The laboratory has the capability to evaluate a material’s ability to withstand mechanical loads for long periods of time at temperatures up to 1100 °C. Additionally, the lab can test a material’s compressive and tensile strength—the resistance to breaking under tension—from room temperature to 1200 °C, as well as impact testing and hot-hardness testing.

Diversity of Computation. by Pruet Boonma

OMP_price_stoneblocks by East Realty

Seamless: Computational Couture by David Goligorsky

TurtleArt by Tinkering Studio

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